CN111843277A - 复合焊条和相关包覆制品 - Google Patents
复合焊条和相关包覆制品 Download PDFInfo
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- CN111843277A CN111843277A CN202010198932.7A CN202010198932A CN111843277A CN 111843277 A CN111843277 A CN 111843277A CN 202010198932 A CN202010198932 A CN 202010198932A CN 111843277 A CN111843277 A CN 111843277A
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- based alloy
- tungsten carbide
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- 239000002131 composite material Substances 0.000 title abstract description 11
- 239000002245 particle Substances 0.000 claims abstract description 106
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 65
- 229910052751 metal Inorganic materials 0.000 claims abstract description 58
- 239000002184 metal Substances 0.000 claims abstract description 56
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 55
- 239000000956 alloy Substances 0.000 claims abstract description 55
- 239000011159 matrix material Substances 0.000 claims abstract description 55
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims abstract description 50
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 33
- 229910000531 Co alloy Inorganic materials 0.000 claims abstract description 31
- 238000005253 cladding Methods 0.000 claims description 41
- 239000000203 mixture Substances 0.000 claims description 33
- 239000000758 substrate Substances 0.000 claims description 28
- 238000000034 method Methods 0.000 claims description 25
- 238000003466 welding Methods 0.000 claims description 23
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 11
- 239000011230 binding agent Substances 0.000 claims description 11
- 229910052796 boron Inorganic materials 0.000 claims description 11
- 229910052710 silicon Inorganic materials 0.000 claims description 11
- 239000010703 silicon Substances 0.000 claims description 11
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 8
- 229910052750 molybdenum Inorganic materials 0.000 claims description 8
- 239000011733 molybdenum Substances 0.000 claims description 8
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 7
- 229910052719 titanium Inorganic materials 0.000 claims description 7
- 239000010936 titanium Substances 0.000 claims description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- 229910052804 chromium Inorganic materials 0.000 claims description 6
- 239000011651 chromium Substances 0.000 claims description 6
- 238000005260 corrosion Methods 0.000 claims description 5
- 230000007797 corrosion Effects 0.000 claims description 5
- 150000004767 nitrides Chemical class 0.000 claims description 5
- 238000000151 deposition Methods 0.000 claims description 4
- 150000001247 metal acetylides Chemical class 0.000 claims description 4
- 230000001143 conditioned effect Effects 0.000 claims 1
- 238000005530 etching Methods 0.000 claims 1
- 239000008187 granular material Substances 0.000 claims 1
- 239000000843 powder Substances 0.000 description 14
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 238000005245 sintering Methods 0.000 description 7
- 230000003746 surface roughness Effects 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 239000011324 bead Substances 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 5
- 239000010941 cobalt Substances 0.000 description 5
- 229910017052 cobalt Inorganic materials 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 239000010955 niobium Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 4
- 229910052721 tungsten Inorganic materials 0.000 description 4
- 239000010937 tungsten Substances 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 238000005552 hardfacing Methods 0.000 description 3
- 239000007791 liquid phase Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 229910052758 niobium Inorganic materials 0.000 description 3
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 3
- 229910021332 silicide Inorganic materials 0.000 description 3
- 229910052715 tantalum Inorganic materials 0.000 description 3
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- VEQPNABPJHWNSG-UHFFFAOYSA-N Nickel(2+) Chemical compound [Ni+2] VEQPNABPJHWNSG-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 2
- BFGKITSFLPAWGI-UHFFFAOYSA-N chromium(3+) Chemical compound [Cr+3] BFGKITSFLPAWGI-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 230000003628 erosive effect Effects 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 229910052735 hafnium Inorganic materials 0.000 description 2
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 2
- 238000007655 standard test method Methods 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- 229910020968 MoSi2 Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 229910033181 TiB2 Inorganic materials 0.000 description 1
- LCKIEQZJEYYRIY-UHFFFAOYSA-N Titanium ion Chemical compound [Ti+4] LCKIEQZJEYYRIY-UHFFFAOYSA-N 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- XHCLAFWTIXFWPH-UHFFFAOYSA-N [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] XHCLAFWTIXFWPH-UHFFFAOYSA-N 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- XTDAIYZKROTZLD-UHFFFAOYSA-N boranylidynetantalum Chemical compound [Ta]#B XTDAIYZKROTZLD-UHFFFAOYSA-N 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- -1 cubic boron nitride Chemical compound 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000009863 impact test Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910000765 intermetallic Inorganic materials 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 238000005453 pelletization Methods 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000007778 shielded metal arc welding Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 229910001935 vanadium oxide Inorganic materials 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3033—Ni as the principal constituent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3046—Co as the principal constituent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/3601—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/067—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds comprising a particular metallic binder
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
Abstract
本发明公开了复合焊条和相关包覆制品。简单来讲,焊条包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分,所述硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒,并且所述镍基合金基体或所述钴基合金基体包含至少一种金属碳化物形成元素。
Description
技术领域
本申请涉及焊条和相关的包覆制品,具体地讲,涉及包含分散在合金基体中的硬颗粒的焊条。
背景技术
为了尽力延长制品或部件的使用寿命,通常对经受恶劣环境或操作条件的制品或部件施加包层。可通过多种技术对金属基材施加复合包层,所述技术包括堆焊、热喷涂、激光包覆、红外包覆或感应包覆。常规的堆焊工艺采用各种组成的耐磨堆焊焊条。一类碳化物耐磨堆焊焊条例如是一种管状条,它由钢管和置于该管中的金属碳化物颗粒构成,并且含或不含有机粘结剂。另一类焊条由在基体合金中部分致密化的金属碳化物颗粒组成。这些焊条构造中的每一个表现出导致沉积具有较差特性和性能的包层的结构问题。例如,管状条通常具有散布于管中的松散粉末和不均匀的粒度分布。这会产生结构不均匀且具有磨损特征的包层。部分致密化的焊条很脆弱,在运输和处理过程中容易断裂。另外,部分致密化的焊条表现出相互连接的孔隙(如管条中填充的粉末),所述孔隙可能被氧化和/或从环境中吸收水分,这可能导致焊接缺陷。
发明内容
鉴于这些缺陷,本文描述了用于制备具有期望的微结构和/或增强的耐磨性和耐腐蚀性的包层的新型焊条组合物。简单来讲,焊条包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分,所述硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒,并且所述镍基合金基体或所述钴基合金基体包含至少一种金属碳化物形成元素。在一些实施方案中,碳化钨颗粒以至少40重量%的量存在于焊条中。
在另一方面,本文描述了复合包覆制品。在一些实施方案中,复合制品包括金属基材和粘附到该基材上的包层,该包层包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分,该硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒。镍基合金基体或钴基合金基体包含至少一种金属碳化物形成元素。如本文中进一步描述,包层可通过堆焊工艺粘附到基材上。
在另一方面,提供了包覆金属基材的方法。在一些实施方案中,一种包覆金属基材的方法包括提供焊条,该焊条包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分以及镍基合金基体或钴基合金基体,所述硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒。在一些实施方案中,镍基合金或钴基合金包含至少一种金属碳化物形成元素。从焊条沉积包层到金属基材上。
在下面的详细描述中进一步描述了这些和其他实施方案。
附图说明
图1提供了根据一些实施方案,相对于由采用粗碳化钨颗粒的焊条形成的现有技术包层,具有本文所述的结构和组成的腐蚀包层的表面粗糙度值。
具体实施方式
通过参考以下具体实施方式和实例以及它们的先前和随后的描述,可以更容易地理解本文描述的实施方案。然而,本文描述的元件、设备和方法不限于在具体实施方式和实例中呈现的特定实施方案。应当认识到,这些实施方案仅仅是本发明原理的说明。在不脱离本发明的实质和范围的情况下,许多修改和调整对于本领域技术人员将是显而易见的。
I.焊条和复合制品
在一个方面,焊条包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分,所述硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒,并且所述镍基合金基体或所述钴基合金基体包含至少一种金属碳化物形成元素。
在一些实施方案中,镍基合金或钴基合金基体的金属碳化物形成元素选自由铬、钼、钛、硅、硼以及它们的各种混合物组成的组。金属碳化物形成元素可以任何所需量存在于合金基体中,包括足以增强从焊条沉积的包层的耐磨性和/或耐腐蚀性的量。金属碳化物形成元素诸如硼和/或硅也可以足以在焊条制造期间增强液相烧结和/或硬颗粒润湿的量存在。例如,金属碳化物形成元素可以小于约10重量%或小于约5重量%的量存在于合金基体中。在一些实施方案中,金属碳化物形成元素的混合物以小于约10重量%或小于约5重量%的量存在于合金基体中。或者,合金基体中金属碳化物形成元素的总和可超过10重量%。在此类实施方案中,总和中包括的每种单独的金属碳化物形成元素可以小于10重量%或小于5重量%的量存在于合金基体中。金属碳化物形成元素的重量百分比是基于整个合金基体组成确定的,并且不限于合金基体的任何局部区域。在一些实施方案中,镍基合金基体或钴基合金基体的液相点小于1200℃或小于1100℃。
在一些实施方案中,焊条的镍基合金基体可具有选自表I的组成。
表I–镍基合金基体
元素 | 量(重量%) |
铬 | 0-30 |
钼 | 0-28 |
钨 | 0-15 |
铌 | 0-6 |
钽 | 0-6 |
钛 | 0-6 |
铁 | 0-30 |
钴 | 0-15 |
铜 | 0-50 |
碳 | 0-2 |
锰 | 0-2 |
硅 | 0-10 |
磷 | 0-10 |
硫 | 0-0.1 |
铝 | 0-1 |
硼 | 0-5 |
镍 | 余量 |
例如,镍基合金基体可包含1-10重量%的铬、0-5重量%的钼、0-10重量%的钛、0-5重量%的硅、0-3重量%的硼、0-15重量%的钨、0-2重量%的碳和余量的镍。此外,在一些实施方案中,焊条的钴基合金可具有选自表II的组成。
表II–钴基合金基体
元素 | 量(重量%) |
铬 | 0-30 |
钨 | 0-15 |
钼 | 0-20 |
镍 | 0-20 |
铁 | 0-25 |
锰 | 0-2 |
硅 | 0-5 |
钒 | 0-5 |
碳 | 0-4 |
硼 | 0-5 |
铜 | 0-5 |
钴 | 余量 |
在一些实施方案中,例如,钴基合金基体可包含3-10重量%的铬、0-5重量%的钼、0-10重量%的钛、0-5重量%的硅、0-3重量%的硼、0-15重量%的钨、0-2重量%的碳和余量的钴。
如本文所述,焊条包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分。该硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒。在一些实施方案中,硬颗粒组分的碳化钨颗粒具有选自表III的平均粒度。
表III–碳化钨平均粒度(μm)
≤40 |
10-43 |
15-40 |
20-43 |
硬颗粒组分的碳化钨颗粒包括粗晶碳化钨、铸造碳化钨、含有量少于3重量%的金属粘结剂的多晶碳化钨、烧结碳化物和/或它们的混合物。硬颗粒组分中采用的烧结碳化钨颗粒可具有任何所需量的金属粘结剂。烧结碳化钨颗粒的金属粘结剂含量可根据包括所需颗粒硬度和耐磨性在内的多种考虑因素进行选择。在一些实施方案中,烧结碳化钨颗粒包含3重量%至20重量%的金属粘结剂。烧结碳化物颗粒的金属粘结剂可包含钴、镍、铁或它们的各种合金。
碳化钨颗粒可以任何所需量存在于焊条中。例如,碳化钨颗粒可以焊条的至少40重量%的量存在。在一些实施方案中,碳化钨颗粒以40-80重量%或50-70重量%的量存在于焊条中。在一些实施方案中,焊条中的大多数碳化钨颗粒是粗晶碳化钨颗粒。例如,焊条中的碳化钨颗粒的至少60%可以是粗晶碳化钨。在一些实施方案中,焊条中的碳化钨颗粒的70-100%是粗晶碳化钨。
除碳化钨颗粒之外,硬颗粒组分还可包含金属碳化物、金属氮化物、金属碳氮化物、金属硼化物、金属硅化物、金属间化合物或其他陶瓷或它们的混合物的颗粒。在一些实施方案中,硬颗粒的金属元素包括铝、硼、硅和/或选自周期表的IVB、VB和VIB族的一种或多种金属元素。本文所述的元素周期表的各族是根据CAS命名法标识的。在一些实施方案中,例如,硬颗粒包含钛、铬、钼、锆、铪、钽、铌、铼、钒、硼或硅或它们的混合物的碳化物。在一些实施方案中,硬颗粒包含铝、硼、硅、钛、锆、铪、钽或铌的氮化物,包括立方氮化硼,或它们的混合物。另外,在一些实施方案中,硬颗粒包含硼化物诸如二硼化钛B4C或硼化钽,或者硅化物诸如MoSi2或Al2O3–SiN。硬颗粒可包含破碎的碳化物、破碎的氮化物、破碎的硼化物、破碎的硅化物或它们的混合物。除碳化钨之外的硬颗粒可具有任何所需的粒度。在一些实施方案中,这些硬颗粒的平均粒度为10μm至100μm或更大。在其他实施方案中,这些硬颗粒的平均粒度小于45μm。例如,硬颗粒可具有选自本文的表III的粒度。
硬组分的颗粒可以均匀地或基本上均匀地分散在焊条的合金基体中。此外,本文所述的焊条可具有任何适于通过堆焊技术施加包层的尺寸。在一些实施方案中,焊条具有圆形或椭圆形的横截面。
在另一方面,本文描述了复合制品。在一些实施方案中,复合制品包括金属基材和粘附到该基材上的包层,该包层包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分,该硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒,并且镍基合金基体或钴基合金基体包含至少一种金属碳化物形成元素。
包层可通过采用具有本文所述组成和特性的焊条的堆焊工艺而粘附到金属基材上。因此,包层可具有本部分I中所述的任何组成特性。例如,包层可包含上述的任何镍基合金基体或钴基合金基体。另外,分散在合金基体中的碳化钨颗粒可具有本部分I中所述的组成和选自表III的平均粒度。
复合制品的包层也可表现出期望的耐磨特性。在一些实施方案中,根据ASTM G76–Standard Test Method for Conducting Erosion Tests by Solid ParticleImpingement Using Gas Jets,包层表现出每克腐蚀性介质小于0.07mm3或小于0.05mm3的腐蚀速率。根据ASTM G65–Standard Test Method for Measuring Abrasion Using theDry Sand/Rubber Wheel Apparatus,规程A,用本文所述的焊条形成的包层也可表现出小于30mm3的调整后体积损失。
包层可以粘附到任何所需的金属基材上。合适的金属基材包括但不限于钢、铁基合金、镍基合金和钴基合金。在一些实施方案中,钢包括碳素钢、合金钢、工具钢或不锈钢。在一个实施方案中,例如,钢基材的碳含量大于0.3重量%。另外,在一些实施方案中,镍基合金基材可以商品名 和/或商购获得,并且钴基合金基材可以商品名和/或商购获得。
金属基材可以呈现各种几何形状。在一些实施方案中,基材具有圆柱形的几何形状,其中内径(ID)表面、外径(OD)表面或这两者可以被包覆。在一些实施方案中,例如,金属基材包括耐磨垫片、造粒模具、轴承、挤出机机筒、挤出机螺杆、流量控制部件、管道或管。在一些实施方案中,包覆的基材用于油井和/或气体钻井、石化、发电、食品和宠物食品行业以及涉及磨损、磨蚀、腐蚀和/或高温的一般工程应用。
在一些实施方案中,本文所述的复合制品的包层表现出磨损或腐蚀的表面。在将本文所述的包层沉积和/或暴露于一种或多种腐蚀性环境之后,例如当包覆制品用于其正常进程中时,该包层的腐蚀表面可通过机械加工或研磨包层而产生。在一些实施方案中,包层的腐蚀表面的表面粗糙度(Ra)小于10μm或小于5μm。在一些实施方案中,腐蚀的包覆表面的表面粗糙度为0.5μm至5μm。值得注意的是,在一些实施方案中,本文所述的包层可在包层寿命的任何点处表现出前述的表面粗糙度值。例如,包层的表面粗糙度可为0.5μm至10μm,而少于50%的包层保留在金属基材上。在包层寿命内保持期望的表面粗糙度值的能力可以至少部分地归因于焊条的细碳化钨粒度,该细碳化钨粒度被携带到沉积的包层中。
图1提供了相对于由采用粗碳化钨颗粒的焊条形成的现有技术包层,具有本文所述的结构和组成的腐蚀包层的表面粗糙度值。如图1所示,本文所述的包层的腐蚀表面大体上更光滑,其粗糙度通常小于5μm。
II.包覆金属基材的方法
在另一方面,提供了包覆金属基材的方法。在一些实施方案中,一种包覆金属基材的方法包括提供焊条,该焊条包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分,所述硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒,并且镍基合金基体或钴基合金基体包含至少一种金属碳化物形成元素。从焊条沉积包层到金属基材上。本文所述方法的焊条和相关包层可具有上面第一部分中描述的任何组成和/或特性。
可通过将硬颗粒组分与粉末镍基合金或粉末钴基合金共混或混合来提供焊条。混合物的组成参数可以与焊条的所需组成参数一致,包括碳化钨颗粒的重量百分比和平均粒度。将硬颗粒粉末合金混合物与有机粘结剂混合,以制造携带混合物的片材。可对有机粘结剂和硬颗粒-粉末合金混合物进行机械加工或处理,以将颗粒混合物捕集在有机粘结剂中。在一个实施方案中,例如,将硬颗粒-粉末合金混合物与3-15体积%的PTFE混合并机械加工,以使PTFE原纤化并捕集颗粒混合物。机械加工可包括轧制、球磨、拉伸、伸长、铺展或它们的组合。在一些实施方案中,将包含硬颗粒-粉末合金混合物的片材进行冷等静压成型。所得片材可具有低弹性模量和高生坯强度。在一些实施方案中,根据美国专利3,743,556、3,864,124、3,916,506、4,194,040和5,352,526中的一项或多项的公开内容制备包含有机粘结剂和硬颗粒-粉末合金混合物的片材,所述专利中的每一篇全文以引用方式并入本文。
随后将片材轧制并切割成所需的长度和厚度。然后对条状片进行液相烧结,从而得到焊条。烧结温度和时间将取决于粉末镍基合金或粉末钴基合金的具体组成。对于本文所述的几种粉末合金,烧结温度通常可以在950℃至1300℃的范围内,烧结时间为20分钟至2小时,以实现焊条的完全或基本上完全致密化。在一些实施方案中,焊条具有小于2体积%的孔隙率或小于1体积%的孔隙率。或者,可以将硬颗粒组分和粉末合金分离成单独的片材。可以如上所述形成各个片材。一旦形成,就可以将片材层叠在一起,轧制并切割成所需长度。然后进行液相烧结以完成焊条的制造。
在其他实施方案中,本文所述的焊条可通过将粉末合金和硬颗粒组分共混并将所得混合物装载到具有所需形状和尺寸的焊条的模具中来制造。随后将混合物在模具中烧结并致密化。在一些实施方案中,粉末合金和硬颗粒组分可以在模具内层叠,使得粉末合金在烧结期间渗入硬颗粒层中。
本文所述的焊条被发现可与用于包覆金属基材的各种堆焊技术一起使用。焊条例如可用于屏蔽金属电弧焊、CO2焊接、金属惰性气体保护焊(MIG/TIG)、埋弧焊和/或等离子弧焊(PTA)。
为了实现本发明的各种目的,已经描述了本发明的各种实施方案。应当认识到,这些实施方案仅仅是本发明原理的说明。在不脱离本发明的实质和范围的情况下,其许多修改和调整对于本领域人员将是显而易见的。
Claims (22)
1.一种焊条,包含:
分散在镍基合金基体或钴基合金基体中的硬颗粒组分,所述硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒,并且所述镍基合金基体或钴基合金基体包含至少一种金属碳化物形成元素。
2.如权利要求1所述的焊条,其中所述至少一种金属碳化物形成元素选自由铬、钼、钛、硅和硼组成的组。
3.如权利要求2所述的焊条,其中所述至少一种金属碳化物形成元素以小于10重量%的量存在于所述镍基合金基体或钴基合金基体中。
4.如权利要求2所述的焊条,其中所述至少一种金属碳化物形成元素以小于5重量%的量存在于所述镍基合金基体或钴基合金基体中。
5.如权利要求1所述的焊条,其中所述碳化钨颗粒包括粗晶碳化钨、铸造碳化钨、烧结碳化物或它们的混合物。
6.如权利要求5所述的焊条,其中所述烧结碳化物颗粒包含量为3重量%至20重量%的金属粘结剂。
7.如权利要求1所述的焊条,其中所述硬颗粒组分还包含选自由金属碳化物、金属氮化物和金属碳氮化物组成的组的颗粒。
8.如权利要求7所述的焊条,其中所述金属碳化物、金属氮化物和金属碳氮化物的颗粒的平均粒度小于45μm。
9.如权利要求1所述的焊条,其中所述硬颗粒组分以至少40重量%的量存在于所述焊条中。
10.如权利要求1所述的焊条,其中所述碳化钨颗粒以40重量%至80重量%的量存在于所述焊条中。
11.如权利要求1所述的焊条,其中所述碳化钨颗粒的至少60%是粗晶碳化钨。
12.如权利要求1所述的焊条,其中所述碳化钨颗粒的一部分的尺寸为20μm至40μm。
13.一种包覆金属基材的方法,包括:
提供焊条,所述焊条包含分散在镍基合金基体或钴基合金基体中的硬颗粒组分,所述硬颗粒组分包含平均粒度小于45μm的碳化钨颗粒,并且所述镍基合金基体或钴基合金基体包含至少一种金属碳化物形成元素;以及
从所述焊条沉积包层到所述金属基材上。
14.如权利要求13所述的方法,其中所述碳化钨颗粒的至少60%是粗晶碳化钨。
15.如权利要求13所述的方法,其中所述至少一种金属碳化物形成元素选自由铬、钼、钛、硅和硼组成的组。
16.如权利要求13所述的方法,其中所述碳化钨颗粒包括粗晶碳化钨、铸造碳化钨、烧结碳化物或它们的混合物。
17.如权利要求13所述的方法,其中所述碳化钨颗粒以40重量%至80重量%的量存在于所述焊条中。
18.如权利要求17所述的方法,其中所述碳化钨颗粒的一部分的尺寸为20μm至40μm。
19.如权利要求13所述的方法,其中根据ASTM G76,所述包层的腐蚀速率小于每克腐蚀性介质0.07mm3。
20.如权利要求13所述的方法,其中根据ASTM G65–规程A,所述包层的调整后体积损失小于30mm3。
21.如权利要求13所述的方法,还包括使所述包层的表面腐蚀,其中所述腐蚀表面的粗糙度(Ra)小于10μm。
22.如权利要求21所述的方法,其中所述腐蚀表面的粗糙度(Ra)小于5μm。
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