CN111621690A - Preparation method of metal ceramic composite grinding roller - Google Patents
Preparation method of metal ceramic composite grinding roller Download PDFInfo
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- CN111621690A CN111621690A CN202010321795.1A CN202010321795A CN111621690A CN 111621690 A CN111621690 A CN 111621690A CN 202010321795 A CN202010321795 A CN 202010321795A CN 111621690 A CN111621690 A CN 111621690A
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
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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
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/06—Cast-iron alloys containing chromium
- C22C37/08—Cast-iron alloys containing chromium with nickel
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Abstract
The invention discloses a preparation method of a metal ceramic composite grinding roller, which comprises the following steps: carrying out surface metallization pretreatment on the ceramic particles; uniformly mixing the pretreated ceramic particles with a binder; adding ceramic powder into the mixture and uniformly mixing; uniformly filling the particle mixture into a foam ceramic boat mold and drying to obtain a ceramic prefabricated member; sequentially fixing the ceramic prefabricated parts on the surface of a grinding roller casting cavity in the circumferential direction and then assembling the box; smelting a wear-resistant alloy material to form molten metal, and controlling the percentage content of each metal in the molten iron; and pouring molten metal into the grinding roller casting cavity to obtain the metal ceramic composite grinding roller compounded by the ceramic prefabricated part and the wear-resistant alloy. The high-chromium cast iron material disclosed by the invention is added with a plurality of metal components, so that a high-chromium cast iron matrix can obtain extremely high hardness and simultaneously has higher toughness, the wear-resisting service life of the high-chromium cast iron matrix is more than 2 times that of common high-chromium cast iron, the cost is only about 1.4 times that of the original high-chromium cast iron, the impact and the vibration generated in the operation process can be effectively resisted, and the stable operation of equipment is ensured.
Description
Technical Field
The invention relates to a preparation method of a metal ceramic composite grinding roller, which is applicable to the thermal power generation industry.
Background
In the thermal power industry, the grinding roller is widely used in a powder making system and is used as a main wear-resistant part, and the wear resistance of the grinding roller directly influences the operation rate of powder making, the quality of pulverized coal, the consumption of the grinding roller and the production cost. Any grinding roller material is abraded seriously under the working condition of pulverizing, so that the coal powder efficiency of the coal mill is reduced after the grinding roller is abraded by serious pits and grooves, and the output of the coal mill is insufficient.
Most of grinding rollers used in the existing thermal power plants are integrally cast by high-hardness and high-wear-resistance metal materials such as high-chromium cast iron and the like, so that the cost is high, and the grinding processing is difficult. If the grinding roller is replaced by recasting due to wear failure, great waste is caused. The service life of the grinding roller can be prolonged by repeatedly overlaying the wear-resistant alloy layer on the surface of the worn grinding roller, the times are limited, the cost is high, the phenomenon that the overlaying layer falls off is easy to occur, meanwhile, the frequent shutdown maintenance of a power plant causes great economic loss, and the service life is generally 6000-plus 8000 hours.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to solve the defects in the prior art, and provides a preparation method of a metal ceramic composite grinding roller, which can ensure that a high-chromium cast iron matrix has high hardness and high toughness, the wear-resisting service life of the high-chromium cast iron matrix is more than 2 times that of common high-chromium cast iron, the cost is only about 1.4 times of the original cost, impact and vibration generated in the operation process can be effectively resisted, and the stable operation of equipment is ensured.
The technical scheme is as follows: the invention relates to a preparation method of a metal ceramic composite grinding roller, which is characterized by comprising the following steps: the method comprises the following steps:
(1) carrying out surface metallization pretreatment on ceramic particles with the particle size of 10-30 meshes;
(2) uniformly mixing the pretreated ceramic particles with a binder according to a certain proportion, wherein the addition amount of the binder is 2-5% of the mass of the ceramic particles;
(3) adding a certain proportion of ceramic powder into the mixture obtained in the step (2) and uniformly mixing to obtain a particle mixture, wherein the particle size of the ceramic powder is 100-500 meshes, and the adding amount is 1-6% of the mass of the mixture;
(4) uniformly loading the particle mixture obtained in the step (3) into a ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 100-200 ℃ for 24-72 hours, and demoulding after drying out of the oven to obtain a ceramic prefabricated member;
(5) sequentially fixing the ceramic prefabricated parts on the surface of a grinding roller casting cavity in the circumferential direction and then assembling the box;
(6) smelting a wear-resistant alloy material to form molten metal, and controlling the percentage content of each metal in the molten iron as follows:
Cr:25-27%,C:2.8-3.3%,Si:0.8-1.5%,Ni:0.8-2.0%,Mo:1.0-2.0%,Cu:0.3-0.8%,Nb:0.3-0.6%,V:0.2-0.6%,W:0.5-1.5%,Mn:0.8-1.5%,S:≤0.04%,P≤0.04%；
(7) testing the molten iron again before casting, and determining that the content components of each metal meet the conditions in the step (6);
(8) and pouring molten metal into the grinding roller casting cavity to obtain the metal ceramic composite grinding roller compounded by the ceramic prefabricated part and the wear-resistant alloy.
Further, the step (1) of the metallization pretreatment of the ceramic particles is to coat the surfaces of the ceramic particles with iron-based, nickel-based or cobalt-based low-melting-point alloy materials.
Further, the ceramic particles in the step (1) are alumina, and the mass content of the alumina particles is 92%, 95% and 99%.
Further, the binder in the step (2) is one or a combination of any more of silica sol, water glass, sodium carbonate and phenolic resin.
Further, the ceramic powder in the step (3) is one or a combination of any several of boron carbide, silicon carbide and yttrium oxide.
Further, the ceramic boat mold in the step (4) is made of one of metal, graphite and foam.
Further, the wear-resistant alloy material in the step (6) is high-chromium cast iron or high-manganese steel.
Further, the surface of the ceramic prefabricated member in the step (4) is in a honeycomb shape or a grid shape, the thickness of the prefabricated member is 20-60mm, and the surface of the ceramic prefabricated member is a curved surface.
Furthermore, the hardness of the high-chromium matrix in the metal ceramic composite grinding roller is 62-64HRC, and the impact strength is 5-8J/cm2。
Has the advantages that: the invention has the following beneficial effects:
(1) the high-chromium cast iron material disclosed by the invention is added with a plurality of metal components, so that a high-chromium cast iron matrix can obtain extremely high hardness and simultaneously has higher toughness, the wear-resisting service life of the high-chromium cast iron matrix is more than 2 times that of common high-chromium cast iron, the cost is only about 1.4 times that of the original high-chromium cast iron, the impact and the vibration generated in the operation process can be effectively resisted, and the stable operation of equipment is ensured;
(2) the working surface of the grinding roller is formed by the abrasion-resistant alloy and the metal ceramic composite material in a staggered mode, is honeycomb-shaped, has double abrasion-resistant performance, and is prolonged by more than 1.5 times compared with the service life of the conventional ceramic composite grinding roller.
Drawings
FIG. 1 is a schematic structural view of a composite grinding roll in accordance with the present invention;
FIG. 2 is a cross-sectional view of the construction of the composite grinding roll of the present invention;
FIG. 3 is a schematic structural view of a ceramic preform according to the present invention.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
Example 1
(1) Carrying out surface metallization pretreatment on alumina particles with the particle size of 10-30 meshes and the mass content of 92%, and coating iron-based alloy materials on the surfaces of the alumina particles;
(2) uniformly mixing the pretreated alumina particles with phenolic resin according to a certain proportion, wherein the addition amount of the phenolic resin is 2 percent of the mass of the ceramic;
(3) adding a certain proportion of silicon oxide powder into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle size of the silicon oxide powder is 200-500 meshes, and the adding amount is 1% of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 100 ℃ for 24 hours, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part, wherein the figure is shown in figure 3;
(5) sequentially fixing the ceramic prefabricated parts on the surface of a grinding roller casting cavity in the circumferential direction and then assembling the box;
(6) smelting high-chromium cast iron to form molten metal, and adding the chemical components and the addition amount into molten iron according to the following mixture ratio (weight percentage) during smelting:
Cr:25.5%,C:3%,Si:1.2%,Ni:0.9%,Mo:1.8%,Cu:0.4%,Nb:0.54%,V:0.25%,W:1.16%,Mn:1%，S:≤0.04%,P≤0.04%；
(7) and (3) testing the molten iron again before casting, and determining that the content components of each metal meet the following conditions: 25.5 percent of Cr, 3 percent of C, 1.2 percent of Si, 0.9 percent of Ni, 1.8 percent of Mo, 0.4 percent of Cu, 0.54 percent of Nb, 0.25 percent of V, 1.16 percent of W, 1 percent of Mn, less than or equal to 0.04 percent of S and less than or equal to 0.04 percent of P;
(8) pouring molten metal into the grinding roller casting cavity to obtain the metal ceramic composite grinding roller compounded by the ceramic prefabricated part and the wear-resistant alloy, as shown in figures 1 and 2.
The thickness of the ceramic preform described in this example was 20 mm.
Tests show that the high-chromium cast iron matrix of the metal ceramic composite grinding roller has the hardness of 62.4HRC and the impact strength of 6.5J/cm2。
The service life of the metal ceramic composite grinding roller is 1.6 times that of the existing ceramic composite grinding roller.
Example 2
(1) Carrying out surface metallization pretreatment on alumina particles with the particle size of 10-30 meshes and the mass content of 95%, and coating nickel-based alloy materials on the surfaces of the alumina particles;
(2) uniformly mixing the pretreated alumina particles and water glass according to a certain proportion, wherein the addition amount of the phenolic resin is 3 percent of the mass of the ceramic;
(3) adding a certain proportion of silicon oxide powder into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle size of the silicon oxide powder is 200-500 meshes, and the adding amount is 3% of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat into a drying oven after compacting, drying for 36 hours at 120 ℃, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part;
(5) sequentially fixing the ceramic prefabricated parts on the surface of a grinding roller casting cavity in the circumferential direction and then assembling the box;
(6) smelting high-chromium cast iron to form molten metal, and adding the chemical components and the addition amount into molten iron according to the following mixture ratio (weight percentage) during smelting:
Cr:26%,C:3%,Si:1.2%,Ni:1.2%,Mo:1.6%,Cu:0.5%,Nb:0.4%,V:0.3%,W:1.0%,Mn:1.2%,S:≤0.04%,P≤0.04%；
(7) and (3) testing the molten iron again before casting, and determining that the content components of each metal meet the following conditions: 26 percent of Cr, 3 percent of C, 1.2 percent of Si, 1.2 percent of Ni, 1.6 percent of Mo, 0.5 percent of Cu, 0.4 percent of Nb, 0.3 percent of V, 1.0 percent of W, 1.2 percent of Mn, less than or equal to 0.04 percent of S and less than or equal to 0.04 percent of P;
(8) and pouring molten metal into the grinding roller casting cavity to obtain the metal ceramic composite grinding roller compounded by the ceramic prefabricated part and the wear-resistant alloy.
The thickness of the ceramic preform described in this example was 30 mm.
Tests show that the high-chromium cast iron matrix of the metal ceramic composite grinding roller has the hardness of 62.6HRC and the impact strength of 7.0J/cm2。
The service life of the metal ceramic composite grinding roller is 1.7 times that of the existing ceramic composite grinding roller.
Example 3
(1) Carrying out surface metallization pretreatment on alumina particles with the particle size of 10-30 meshes and the mass content of 99%, and coating cobalt-based alloy materials on the surfaces of the alumina particles;
(2) uniformly mixing the pretreated alumina particles and sodium carbonate according to a certain proportion, wherein the addition of the phenolic resin is 4% of the mass of the ceramic;
(3) adding a certain proportion of silicon oxide powder into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle size of the silicon oxide powder is 200-500 meshes, and the adding amount is 5% of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying for 48 hours at 150 ℃, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part;
(5) sequentially fixing the ceramic prefabricated parts on the surface of a grinding roller casting cavity in the circumferential direction and then assembling the box;
(6) smelting high-chromium cast iron to form molten metal, and adding the chemical components and the addition amount into molten iron according to the following mixture ratio (weight percentage) during smelting:
Cr:26%,C:3.1%,Si:1.2%,Ni:1.5%,Mo:1.6%,Cu:0.6%,Nb:0.5%,V:0.5%,W:1.2%,Mn:1.2%,S:≤0.04%,P≤0.04%；
(7) and (3) testing the molten iron again before casting, and determining that the content components of each metal meet the following conditions: 26 percent of Cr, 3.1 percent of C, 1.2 percent of Si, 1.5 percent of Ni, 1.6 percent of Mo, 0.6 percent of Cu, 0.5 percent of Nb, 0.5 percent of V, 1.2 percent of W, 1.2 percent of Mn, less than or equal to 0.04 percent of S and less than or equal to 0.04 percent of P;
(8) and pouring molten metal into the grinding roller casting cavity to obtain the metal ceramic composite grinding roller compounded by the ceramic prefabricated part and the wear-resistant alloy.
The thickness of the ceramic preform described in this example was 40 mm.
Tests show that the high-chromium cast iron matrix of the metal ceramic composite grinding roller has the hardness of 63.0HRC and the impact strength of 7.5J/cm2。
The service life of the metal ceramic composite grinding roller is 1.75 times that of the existing ceramic composite grinding roller.
Example 4
(1) Carrying out surface metallization pretreatment on alumina particles with the particle size of 10-30 meshes and the mass content of 95%, and coating iron-based alloy materials on the surfaces of the alumina particles;
(2) uniformly mixing the pretreated alumina particles with phenolic resin according to a certain proportion, wherein the addition amount of the phenolic resin is 5 percent of the mass of the ceramic;
(3) adding a certain proportion of silicon oxide powder into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle diameter of the silicon oxide powder is 200-500 meshes, and the adding amount is 6 percent of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 200 ℃ for 72 hours, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part;
(5) sequentially fixing the ceramic prefabricated parts on the surface of a grinding roller casting cavity in the circumferential direction and then assembling the box;
(6) smelting high-chromium cast iron to form molten metal, and adding the chemical components and the addition amount into molten iron according to the following mixture ratio (weight percentage) during smelting:
Cr:27%,C:3.3%,Si:1.5%,Ni:2.0%,Mo:2.0%,Cu:0.8%,Nb:0.6%,V:0.6%,W:1.5%,Mn:1.5%,S:≤0.04%,P≤0.04%；
(7) and (3) testing the molten iron again before casting, and determining that the content components of each metal meet the following conditions: 27 percent of Cr, 3.3 percent of C, 1.5 percent of Si, 2.0 percent of Ni, 2.0 percent of Mo, 0.8 percent of Cu, 0.6 percent of Nb, 0.6 percent of V, 1.5 percent of W, 1.5 percent of Mn, less than or equal to 0.04 percent of S and less than or equal to 0.04 percent of P;
(8) and pouring molten metal into the grinding roller casting cavity to obtain the metal ceramic composite grinding roller compounded by the ceramic prefabricated part and the wear-resistant alloy.
The thickness of the ceramic preform described in this example was 60 mm.
Tests show that the high-chromium cast iron matrix of the metal ceramic composite grinding roller has the hardness of 64HRC and the impact strength of 8J/cm2。
The service life of the metal ceramic composite grinding roller is 1.8 times that of the existing ceramic composite grinding roller.
The high-chromium cast iron material disclosed by the invention is added with a plurality of metal components, so that a high-chromium cast iron matrix can obtain extremely high hardness and simultaneously has higher toughness, the wear-resisting service life of the high-chromium cast iron matrix is more than 2 times that of common high-chromium cast iron, the cost is only about 1.4 times that of the original high-chromium cast iron, the impact and the vibration generated in the operation process can be effectively resisted, and the stable operation of equipment is ensured; the working surface of the grinding roller is formed by the abrasion-resistant alloy and the metal ceramic composite material in a staggered mode, is honeycomb-shaped, has double abrasion-resistant performance, and is prolonged by more than 1.5 times compared with the service life of the conventional ceramic composite grinding roller.
Although the present invention has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (9)
1. The preparation method of the metal ceramic composite grinding roller is characterized by comprising the following steps of: the method comprises the following steps:
(1) carrying out surface metallization pretreatment on ceramic particles with the particle size of 10-30 meshes;
(2) uniformly mixing the pretreated ceramic particles with a binder according to a certain proportion, wherein the addition amount of the binder is 2-5% of the mass of the ceramic particles;
(3) adding a certain proportion of ceramic powder into the mixture obtained in the step (2) and uniformly mixing to obtain a particle mixture, wherein the particle size of the ceramic powder is 100-500 meshes, and the adding amount is 1-6% of the mass of the mixture;
(4) uniformly loading the particle mixture obtained in the step (3) into a ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 100-200 ℃ for 24-72 hours, and demoulding after drying out of the oven to obtain a ceramic prefabricated member;
(5) sequentially fixing the ceramic prefabricated parts on the surface of a grinding roller casting cavity in the circumferential direction and then assembling the box;
(6) smelting a wear-resistant alloy material to form molten metal, and controlling the percentage content of each metal in the molten iron as follows:
Cr:25-27%,C:2.8-3.3%,Si:0.8-1.5%,Ni:0.8-2.0%,Mo:1.0-2.0%,Cu:0.3-0.8%,Nb:0.3-0.6%,V:0.2-0.6%,W:0.5-1.5%,Mn:0.8-1.5%,S:≤0.04%,P≤0.04%；
(7) testing the molten iron again before casting, and determining that the content components of each metal meet the conditions in the step (6);
(8) and pouring molten metal into the grinding roller casting cavity to obtain the metal ceramic composite grinding roller compounded by the ceramic prefabricated part and the wear-resistant alloy.
2. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: the metallization pretreatment of the ceramic particles in the step (1) is to coat the surfaces of the ceramic particles with iron-based, nickel-based or cobalt-based low-melting-point alloy materials.
3. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: the ceramic particles in the step (1) are alumina, and the mass content of the alumina particles is 92%, 95% and 99%.
4. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: the binder in the step (2) is one or the combination of any more of silica sol, water glass, sodium carbonate and phenolic resin.
5. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: and (3) the ceramic powder is one or the combination of any more of boron carbide, silicon carbide and yttrium oxide.
6. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: and (4) the ceramic boat mould is made of one of metal, graphite and foam.
7. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: and (4) the wear-resistant alloy material in the step (6) is high-chromium cast iron or high-manganese steel.
8. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: and (4) the surface of the ceramic prefabricated part in the step (4) is in a honeycomb shape or a grid shape, the thickness of the prefabricated part is 20-60mm, and the surface of the ceramic prefabricated part is a curved surface.
9. The method for manufacturing a cermet composite grinding roller according to claim 1, characterized in that: the hardness of the high-chromium matrix in the metal ceramic composite grinding roller is 62-64HRC, and the impact strength is 5-8J/cm2。
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| CN112251676A (en) * | 2020-10-22 | 2021-01-22 | 北京华锦源耐磨材料有限公司 | Composite wear-resistant steel plate and preparation method thereof |
| CN113414377A (en) * | 2021-07-12 | 2021-09-21 | 南通高欣耐磨科技股份有限公司 | Assembling method of composite casting roller skin |
| CN114734015A (en) * | 2022-05-12 | 2022-07-12 | 昆明理工大学 | Method for improving wear-resisting and corrosion-resisting properties of shaft sleeve |
| CN114833338A (en) * | 2022-04-25 | 2022-08-02 | 西安交通大学 | Chemical plating NiMo modified TiB 2 -TiC particle reinforced high manganese steel base composite material and preparation method thereof |
| CN116079027A (en) * | 2022-12-05 | 2023-05-09 | 桐乡磊石微粉有限公司 | Preparation method of centrifugal casting metal ceramic composite grinding roller for glass fiber industry |
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| CN114833338A (en) * | 2022-04-25 | 2022-08-02 | 西安交通大学 | Chemical plating NiMo modified TiB 2 -TiC particle reinforced high manganese steel base composite material and preparation method thereof |
| CN114734015A (en) * | 2022-05-12 | 2022-07-12 | 昆明理工大学 | Method for improving wear-resisting and corrosion-resisting properties of shaft sleeve |
| CN116079027A (en) * | 2022-12-05 | 2023-05-09 | 桐乡磊石微粉有限公司 | Preparation method of centrifugal casting metal ceramic composite grinding roller for glass fiber industry |
| CN116079027B (en) * | 2022-12-05 | 2024-02-06 | 桐乡磊石微粉有限公司 | Preparation method of centrifugal casting metal ceramic composite grinding roller for glass fiber industry |
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