CN111254393B - 一种耐磨推土机传动轴零件的制备方法 - Google Patents
一种耐磨推土机传动轴零件的制备方法 Download PDFInfo
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Abstract
本发明属于轴类零件制造技术领域,具体涉及一种耐磨推土机传动轴的制备方法,推土机传动轴零件基体经过淬火、高温回火、粗精加工后采用离子镀方法进行渗碳处理,然后再通过离子镀和磁控溅射复合方法沉积表面的NbTaZrC梯度涂层,沉积时采用2个C离子镀靶,1个Nb磁控溅射靶,1个Ta磁控溅射靶和1个Zr磁控溅射靶。本发明能提高推土机传动轴的表面硬度,增强所沉积涂层与传动轴零件基体的附着性能,从而改善传动轴零件的耐磨性能,有效提高表面处理效率和传动轴的使用寿命。
Description
技术领域
本发明属于轴类零件制造技术领域,具体涉及一种耐磨推土机传动轴零件的制备方法。
背景技术
推土机属于循环作业的铲土运输机械,作业工况极其恶劣,工作载荷变化剧烈,导致推土机传统系统零件的使用寿命远低于挖掘机等工程机械,因此对推土机传动系统零件的设计和使用要求更加严格。传动轴是推土机传动系统中支承齿轮、轴承等转动零件并与之一起回转以传递运动、扭矩或弯矩的机械零件,是传动系统中的核心部件。传动轴的失效是由于其与配合零件之间的结合面因为磨损过多而松动,致使扭矩传输失稳,传动系统的零件冲击和振动加剧,从而造成传动系统的齿轮和轴承的过早失效,对生产和驾驶员人身安全造成极大的安全隐患。
目前,推土机传动轴的主要失效方式是磨损,其磨损过程可以分为摩擦磨损-磨粒磨损-粘着及疲劳磨损三个阶段。为提高推土机传动轴的表面摩擦磨损性能,通常采用降低传动轴单位面积应力和提高传动轴单位面积强度的途径以提高传动轴的抗磨损能力和可靠性。但是,通过增大传动轴尺寸来降低传动轴表面应力会增加传动系统的体积和重量,对于结构尺寸和空间大小有严格要求的推土机传动系统来说是难以实现的;而采用传统的表面热处理方法提高传动轴表面硬度的同时会伴随较大的变形,甚至会因为传统热处理后的表面硬度不足以及不均匀而导致传动轴在高速、重载条件下出现表面过早失效。因此,延长推土机传动轴的使用寿命具有重要的意义。
由于碳化物涂层具备高硬度,高强度,化学性质稳定,耐热,耐磨损等优良特性,因此有望通过在零件表面制备碳化物涂层或通过金属表层的碳化处理来提高零件的耐磨性。
目前制备碳化物涂层的技术主要有喷涂、渗碳以及气相沉积等方法。其中,喷涂是指借助压力或离心力,将涂层材料喷射到工件的表面,该方法制备涂层虽然具有较高的喷涂效率,但是涂层与工件基体的结合力很差,而且涂层的表面非常粗糙,不适合高速高载的恶劣工况条件;渗碳是指使碳原子渗入到钢类工件表层的过程,从而使工件表面获得很高的表面硬度,提高其耐磨性能。但是由于渗碳温度达到800℃以上,渗碳后工件仍要进行淬火和回火,使得工件表面发生较大变形,无法保证零件的尺寸和形状精度,处理完的零件仍需修磨和再加工,而且渗碳及后续热处理时间通常达到30小时以上,效率低下;气相沉积法,尤其是物理气相沉积(PVD),制备的涂层表面具有极高的硬度、强度,以及良好的热稳定性和耐磨性,而且该制备工艺温度可控制在400℃以下,不会导致零件基体组织变化,表面尺寸和形状精度也不受影响。因此,物理气相沉积技术(PVD)在表面处理领域极具潜力。但是,直接在推土机传动轴零件表面制备PVD碳化物涂层,会由于基体硬度、弹性模量、热膨胀系数等性能与涂层材料相差较大,无法获得较高结合力的PVD涂层,使得PVD涂层过早脱落和失效。中国专利CN101058870A模具表面采用单一的PVD涂层,涂层与基体的结合力差以及PVD涂层同基体的力学匹配差是限制PVD涂层高硬度及低摩擦系数等优势发挥的重要因素。中国专利CN103727180A直接在碳钢表面制备了耐磨陶瓷涂层和金刚石涂层,由于基体较软的硬度无法支撑涂层以及基体与涂层之间明显的性能差异导致制备的涂层使用性能无法满足诸多实际使用要求,尤其是高速、重载、交变载荷工况条件下涂层很快脱落和磨损。
发明内容
本发明目的在于提供一种耐磨推土机传动轴零件的制备方法,能提高传动轴零件表面的硬度,增强所沉积涂层与零件基体的附着性能,从而改善传动轴零件的耐磨、抗压和表面抗胶合等综合性能,有效提高传动轴表面处理效率和工件的使用寿命。
本发明所述的耐磨推土机传动轴零件的制备方法,传动轴零件基体经过淬火、高温回火、粗精加工后采用离子镀方法进行渗碳处理,然后再通过离子镀和磁控溅射复合方法沉积表面的NbTaZrC梯度涂层,沉积时采用2个C离子镀靶,1个Nb磁控溅射靶,1个Ta磁控溅射靶和1个Zr磁控溅射靶;
具体包括如下步骤:
(1)传动轴机械加工:传动轴零件毛坯→淬火→高温回火→粗加工→半精加工→去应力回火→精加工,通过淬火及高温回火处理能够保证芯部足够的韧性和抗冲击变形能力;
(2)传动轴表面预处理:采用金属清洗剂去除工件表面油污,漂洗烘干;
(3)传动轴表面处理:将零件依次放入酒精和丙酮中,超声清洗各35min,去除表面杂志和其它附着物,干燥充分后迅速放入PVD复合镀膜机,抽真空至6.5×10-3Pa,加热至300℃,保温35min;
(4)传动轴表面辉光清洗:通Ar气,其压力为2.2-2.5Pa,温度300℃,打开偏压电源电压820V,占空比0.2,表面辉光放电清洗20min;
(5)传动轴表面离子清洗:偏压调至750V,占空比0.3,Ar气压1.7Pa,温度270℃,开启离子源,离子清洗20min,开启电弧C靶电源,C靶电流125A,离子轰击4-5min;
(6)传动轴离子镀渗碳:C靶离子镀电源调为120A,Ar气压1.1-1.2Pa,基体偏压调至400V,温度260℃,进行离子渗碳30-35min;
(7)沉积碳化物梯度涂层:Ar气压调为0.9-1.0Pa,偏压降为170V,沉积温度240℃,C靶电流调至55A,打开磁控溅射Nb靶电流80A,磁控溅射Ta靶电流70A,磁控溅射Zr靶电流60A,沉积NbTaZrC复合层3min;其它参数不变,增加C靶电流,C靶电流每次增加5A,沉积NbTaZrC复合层3min,直至C靶电流增至100A,再沉积NbTaZrC复合层3min;
(8)后处理:关闭各靶电源、离子源及气体源,涂层结束。
零件基体材料为20CrMnTi,20CrMnMo,20NiCrMoH,22CrNi2MoNbH,40CrMn等中低碳钢及其合金钢中的一种。
所制得的推土机传动轴零件具有以下结构:在零件基体表面表面向外依次具有表面渗碳扩散层、NbTaZrC碳化物梯度涂层。
本发明通过物理气相沉积技术进行表面渗碳及涂层处理的耐磨推土机传动轴的制备工艺,将碳化物涂层、PVD方法与渗碳技术相结合,在碳化物涂层与工件基体间通过离子溅射的方法制备一个渗碳扩散层,即对传动轴工件表面先通过离子溅射的方法进行表面渗碳处理,然后再采用离子镀和磁控溅射复合方法沉积成分梯度变化的NbTaZrC碳化物涂层。
本发明通过表面离子渗碳处理,使碳原子渗入到零件基体内部,并随着深度的增加,碳原子的浓度逐渐减小,有利于形成高硬度和强度的碳化物梯度扩散层,从而为后续NbTaZrC碳化物涂层的制备提供强有力的支撑基体以及良好的结合性能;而通过离子镀和磁控溅射复合方法制备的成分渐变的NbTaZrC碳化物梯度涂层,可以减缓涂层与基体材料之间的性能差异,改善结构和性能上的匹配性能,增大涂层与基体的结合力和涂层的耐冲击性能。同时,该NbTaZrC碳化物梯度涂层中,C元素可降低涂层表面的摩擦系数,降低推土机传动轴工作过程中的摩擦磨损,加入Nb和Ta元素提高了涂层的硬度、强度和抗压、耐磨、耐蚀性能,Zr元素对涂层起到固溶强化作用,提高了涂层的强度和抗磨损特性。成分渐变的NbTaZrC梯度碳化物涂层能够阻止涂层裂纹的扩展,可改善工件的物理机械性能。
本发明与现有技术相比,具有以下有益效果。
本发明制备工艺可增强涂层与基体的附着性能100%以上,减小工作过程中的摩擦和粘结,表面硬度提高2倍以上,从而提高了推土机传动轴的表面耐磨性能,由于采用物理气相沉积技术进行渗碳和涂层处理,缩短工艺处理时间80%以上,延长推土机传动轴的使用寿命一倍以上,降低传动轴的维护和保养成本50%以上。同时,由于该制备工艺温度可控制在300℃以下,不会导致传动轴零件基体组织性能退化,表面尺寸和形状精度不受影响,处理完后无需进行修磨和再加工,可作为零件的最终处理工艺。
附图说明
图1为实施例1制备的推土机传动轴零件的表面结构示意图。
图中:1、零件基体,2、表面渗碳扩散层,3、NbTaZrC碳化物梯度涂层。
具体实施方式
下面给出本发明的两个最佳实施例。
本发明所述的推土机传动轴零件为可用于生产制造各种形状和规格的推土机传动轴的零件。
实施例1
本发明所述的耐磨推土机传动轴零件的制备方法,传动轴零件基体材料为20CrMnTi,,传动轴零件基体经过淬火、高温回火、粗精加工后采用离子镀方法进行渗碳处理,然后再通过离子镀和磁控溅射复合方法沉积表面的NbTaZrC梯度涂层,沉积时采用2个C离子镀靶,1个Nb磁控溅射靶,1个Ta磁控溅射靶和1个Zr磁控溅射靶;
具体包括如下步骤:
(1)传动轴加工:零件基体毛坯→淬火(840~890℃,水冷)→高温回火(510~550℃,水冷)→粗加工→半精加工→去应力回火(480~520℃,空冷)→精加工(表面粗糙度Ra0.8μm,加工尺寸:公差下限);
(2)传动轴表面预处理:采用金属清洗剂去除工件表面油污,漂洗烘干;
(3)传动轴表面处理:将零件依次放入酒精和丙酮中,超声清洗各35min,去除表面杂志和其它附着物,干燥充分后迅速放入PVD复合镀膜机,抽真空至6.5×10-3Pa,加热至300℃,保温35min;
(4)传动轴表面辉光清洗:通Ar气,其压力为2.2-2.5Pa,温度300℃,打开偏压电源电压820V,占空比0.2,表面辉光放电清洗20min;
(5)传动轴表面离子清洗:偏压调至750V,占空比0.3,Ar气压1.7Pa,温度270℃,开启离子源,离子清洗20min,开启电弧C靶电源,C靶电流125A,离子轰击4-5min;
(6)离子镀渗碳:C靶离子镀电源调为120A,Ar气压1.1-1.2Pa,基体偏压调至400V,温度260℃,进行离子渗碳30-35min;
(7)沉积碳化物梯度涂层:Ar气压调为0.9-1.0Pa,偏压降为170V,沉积温度240℃,C靶电流调至55A,打开磁控溅射Nb靶电流80A,磁控溅射Ta靶电流70A,磁控溅射Zr靶电流60A,沉积NbTaZrC复合层3min;其它参数不变,增加C靶电流,C靶电流每次增加5A,沉积NbTaZrC复合层3min,直至C靶电流增至100A,再沉积NbTaZrC复合层3min;
(8)后处理:关闭各靶电源、离子源及气体源,涂层结束。
如图1,本实施例制得的耐磨推土机传动轴零件具有以下结构:在零件基体1表面由向外依次具有表面渗碳扩散层2、NbTaZrC碳化物梯度涂层3。
本实施例所制得的NbTaZrC耐磨涂层表面显微硬度达到HV2750,相比单独传统渗碳工艺的表面硬度(HV650)提高了3倍多;结合强度为72-77N,相比单纯PVD涂层的结合强度(28-34N)提高了100-170%;涂层厚度为1.82μm,涂层表面粗糙度达到Ra 84nm。在相同的摩擦实验条件下(CETR UMT球盘摩擦磨损试验机,往复直线运动,对磨球为表面硬度HRC55-60的轴承钢,加载载荷80N,滑动速度10mm/s,对磨时间30min),本发明制备的耐磨涂层的磨损率只有2.12-2.35×10-6mm3/N·m,与传统的未加渗碳层的TiAlN氮化物涂层相比,磨损率降低了33%以上。而且整个有效渗碳及涂层时间为1.2h,只有传统渗碳工艺处理时间的4%,而且没有后续的修磨和再加工工序。
实施例2
本发明所述的耐磨推土机传动轴零件的制备方法,推土机传动轴零件基体材料为40CrMn,传动轴零件基体经过淬火、高温回火、粗精加工后采用离子镀方法进行渗碳处理,然后再通过离子镀和磁控溅射复合方法沉积表面的NbTaZrC梯度涂层,沉积时采用2个C离子镀靶,1个Nb磁控溅射靶,1个Ta磁控溅射靶和1个Zr磁控溅射靶;
具体包括如下步骤:
(1)传动轴机械加工:零件基体毛坯→淬火(900~930℃,油淬)→高温回火(540~600℃,
空冷)→粗加工→半精加工→去应力回火(510~570℃,油冷)→精加工(表面粗糙度Ra0.8μm,加工尺寸:公差下限);
(2)传动轴表面预处理:采用金属清洗剂去除工件表面油污,漂洗烘干;
(3)传动轴表面处理:将零件依次放入酒精和丙酮中,超声清洗各35min,去除表面杂志和其它附着物,干燥充分后迅速放入PVD复合镀膜机,抽真空至6.5×10-3Pa,加热至300℃,保温35min;
(4)传动轴表面辉光清洗:通Ar气,其压力为2.2-2.5Pa,温度300℃,打开偏压电源电压820V,占空比0.2,表面辉光放电清洗20min;
(5)传动轴表面离子清洗:偏压调至750V,占空比0.3,Ar气压1.7Pa,温度270℃,开启离子源,离子清洗20min,开启电弧C靶电源,C靶电流125A,离子轰击4-5min;
(6)离子镀渗碳:C靶离子镀电源调为120A,Ar气压1.1-1.2Pa,基体偏压调至400V,温度260℃,进行离子渗碳30-35min;
(7)沉积碳化物梯度涂层:Ar气压调为0.9-1.0Pa,偏压降为170V,沉积温度240℃,C靶电流调至55A,打开磁控溅射Nb靶电流80A,磁控溅射Ta靶电流70A,磁控溅射Zr靶电流60A,沉积NbTaZrC复合层3min;其它参数不变,增加C靶电流,C靶电流每次增加5A,沉积NbTaZrC复合层3min,直至C靶电流增至100A,再沉积NbTaZrC复合层3min;
(8)后处理:关闭各靶电源、离子源及气体源,涂层结束。
本实施例制备的NbTaZrC耐磨涂层表面显微硬度达到HV2740,结合强度为73-79N,涂层厚度为1.78μm,涂层表面粗糙度达到Ra 87nm,整个有效渗碳及涂层时间约为1.2h。
Claims (1)
1.一种耐磨推土机传动轴零件的制备方法,其特征在于:传动轴零件基体材料为20CrMnTi、20CrMnMo、20NiCrMoH、22CrNi2MoNbH、40CrMn中低碳钢及其合金钢中的一种,在零件基体表面由内向外依次为具有表面渗碳扩散层、NbTaZrC碳化物梯度涂层;推土机传动轴零件基体经过淬火、高温回火、粗精加工后采用离子镀方法进行渗碳处理,然后再通过离子镀和磁控溅射复合方法沉积表面的NbTaZrC梯度涂层,沉积时采用2个C离子镀靶,1个Nb磁控溅射靶,1个Ta磁控溅射靶和1个Zr磁控溅射靶,具体包括如下步骤:
(1)传动轴机械加工:传动轴零件基体毛坯→淬火→高温回火→粗加工→半精加工→去应力回火→精加工;
(2)传动轴表面预处理:采用金属清洗剂去除工件表面油污,漂洗烘干;
(3)传动轴表面处理:将零件依次放入酒精和丙酮中,超声清洗各35min,去除表面杂志和其它附着物,干燥充分后迅速放入PVD复合镀膜机,抽真空至6.5×10-3Pa,加热至300℃,保温35min;
(4)传动轴表面辉光清洗:通Ar气,其压力为2.2-2.5Pa,温度300℃,打开偏压电源电压820V,占空比0.2,表面辉光放电清洗20min;
(5)传动轴表面离子清洗:偏压调至750V,占空比0.3,Ar气压1.7Pa,温度270℃,开启离子源,离子清洗20min,开启电弧C靶电源,C靶电流125A,离子轰击4-5min;
(6)传动轴离子镀渗碳:C靶离子镀电源调为120A,Ar气压1.1-1.2Pa,基体偏压调至400V,温度260℃,进行离子渗碳30-35min;
(7)沉积碳化物梯度涂层:Ar气压调为0.9-1.0Pa,偏压降为170V,沉积温度240℃,C靶电流调至55A,打开磁控溅射Nb靶电流80A,磁控溅射Ta靶电流70A,磁控溅射Zr靶电流60A,沉积NbTaZrC复合层3min;其它参数不变,增加C靶电流,C靶电流每次增加5A,沉积NbTaZrC复合层3min,直至C靶电流增至100A,再沉积NbTaZrC复合层3min;
(8)后处理:关闭各靶电源、离子源及气体源,涂层结束。
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