CN112553498B - Copper-nodular cast iron bimetal hydraulic wear-resistant part and preparation method thereof - Google Patents
Copper-nodular cast iron bimetal hydraulic wear-resistant part and preparation method thereof Download PDFInfo
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Abstract
The invention discloses a copper-nodular cast iron bimetal hydraulic wear-resistant part and a preparation method thereof, and belongs to the technical field of welding and connection. The welding method is applied to instantly heat and melt the intermediate alloy and quickly solidify the intermediate alloy to form metallurgical bonding with the matrix, so that reliable connection of the nodular cast iron and the manganese brass is realized, and the method comprises the following steps: a. determining the composition of the wear-resistant alloy for preparing the ductile cast iron bimetal hydraulic part, wherein the alloy consists of two layers of metals, the first layer is a copper alloy containing elements such as silicon, titanium and the like, and the second layer is a manganese brass alloy; b. the surface of the nodular cast iron is mechanically and chemically treated to remove oil stains and oxides; c. prefabricating a copper alloy intermediate layer on the surface of the nodular cast iron by adopting an electric spark deposition method, and forming compact metallurgical bonding with the nodular cast iron; d. preparing a wear-resistant alloy layer by adopting a cold welding method; e, carrying out heat treatment on the bimetal material under the protection of argon. The room temperature thermal conductivity of the copper alloy and ductile cast iron bimetal is 110-118W/(mK), and the 150 ℃ thermal conductivity is 119-125W/(mK); the friction coefficient of the lubricating oil is 0.101-0.105.
Description
Technical Field
The invention relates to a copper-nodular cast iron bimetal hydraulic wear-resistant part and a preparation method thereof.
Background
The plunger pump is an important component of a hydraulic system, is used as an important energy conversion element in the field of the hydraulic system to output controllable high-pressure fluid outwards, controls the change of the output flow of the pump by changing the rotating speed of the pump and a variable device, changes the size of an external load or adjusts a pump pressure regulating device to realize the change of the output pressure of the pump, realizes the action of a hydraulic actuating mechanism, and completes the control of linear motion or rotary motion. The plunger pump assembly has the core components of a swing seat, a valve plate, a cylinder body and other friction pair components, when the pump runs, a plunger reciprocates in the cylinder body, and the components serving as the friction pair can cause surface abrasion, fatigue pitting corrosion or fatigue fracture due to high speed, heavy load, low geometric accuracy of the kinematic pair, stress concentration, overhigh lateral specific pressure and the like, or cause the surface of the friction pair component to generate material adhesion phenomenon due to overlarge limiting pressure-speed ratio to fail; along with the increase of the friction loss of the friction pair component, the abnormal heating of the hydraulic pump is induced, the temperature is overhigh, the expansion of the hydraulic system component is caused, and the phenomenon that the hydraulic valve is blocked due to the damage of the fit clearance of the component is induced. The wear resistance of the friction pair material in the plunger pump is good and bad, and the service life of the plunger pump is limited, and the fundamental guarantee that the high-pressure bearing field can be carried out with breakthrough progress is provided; the key to improving the quality of the hydraulic product is to select a proper friction pair material and a better manufacturing process method. Therefore, the base material of friction pair parts such as the swing seat, the port plate and the cylinder body needs certain hardness and strength, and the end surfaces of the base material need good wear resistance, friction reduction, heat conductivity and high-temperature fatigue resistance. The bimetal material structure not only meets the matching requirement of a friction pair component on the material, but also improves the comprehensive performance of the component, and is one of the development trends of the material for the high-pressure high-speed high-power plunger pump. At present, the friction pair part of the plunger pump adopts a plurality of bimetallic materials of copper-steel combination, and the manufacturing methods comprise fusion welding, gas welding, brazing, explosion welding, solid diffusion welding, casting, mechanical inlaying, deposition, powder metallurgy sintering, rolling composite method and the like, such as Chinese invention patents CN 201010574604.9, CN201210234085.0, CN 201310712523.4, CN201510789408.6, CN201610320678.7, CN201610502247.2 and CN 201711008255.2.
In recent years, plunger pumps are developed towards high efficiency, long service life, low noise and miniaturization, and especially high-pressure plunger pumps with rated pressure higher than 35MPa and rotating speed higher than 1800r/min put higher demands on important technical indexes such as volumetric efficiency of a plunger pump cylinder body, wear resistance of a core friction pair part, fatigue life and the like. The nodular cast iron has good casting performance, is easy to perform mechanical cutting processing, has the characteristics of high strength, plasticity, toughness, wear resistance, heat resistance, mechanical impact resistance, high temperature resistance or low temperature resistance, corrosion resistance, size stability and the like, is used for replacing steel to produce friction pair parts in a plunger pump assembly, has high dimensional precision, good strength and wear resistance, can realize the characteristics of weight reduction and noise reduction, and is favored by manufacturers of hydraulic systems. In 2015, Jon Sheahan, Duraba, USA, visits China Association for the Hydraulic pneumatic seal industry and proposes that nodular cast iron is expected to replace low carbon steel and alloy steel to manufacture copper-nodular cast iron bimetal hydraulic friction pair components, and development targets of light weight, integration, miniaturization and the like of hydraulic products are achieved. The method of making bimetallic material applied to copper-steel combinations is equally applicable to copper-ductile iron. The preparation technology of the copper-nodular cast iron bimetal hydraulic friction pair component firstly dates back to the seventies of the last century, and the Su Union V.V.Vologdin adopts silver alloy as brazing filler metal and steel as a middle layer, so that the bronze-cast iron bimetal hydraulic component connection is realized. In the process of connecting the copper alloy and the bimetallic component of the nodular cast iron, when the heating temperature of carbon in the nodular cast iron is higher than 930K, the carbon is easy to decarbonize, a large amount of air holes are formed on the side of the connecting copper alloy, and the interface cannot form tight combination and fall off. In 2005, Toshinari Yamazaki, university of Fushan Japan, manufactured a tin bronze-ductile iron bimetallic material by using a casting method after FeO decarburization; in 2011, Toshinari Yamazaki oxidizes nodular cast iron in the air again, and then heats the nodular cast iron at a casting temperature of 1203K to realize copper-nodular cast iron bimetal connection, wherein the interface tensile strength is 164Mpa, and the elongation is 4.2%. Research on related materials, technologies and processes of plunger pump friction pair components is actively carried out in various hydraulic enterprises, scientific research institutions and colleges in China, and manufacturing methods include surfacing, spraying, composite pouring, surface alloying, powder sintering and the like, such as Chinese invention patents CN199110009101.3 and CN 201911169466.3. The problems with the manufacture of copper-ductile iron bimetallic friction pair components include the following: on one hand, the physical, chemical and mechanical properties of the nodular cast iron and the copper alloy are greatly different to influence the interface bonding performance, and the traditional sintering method is easy to generate holes on the interface and difficult to realize tight connection; the second aspect is that the copper alloy is easy to soften by adopting a melting welding or high-temperature processing method, the copper alloy bears high pressure, friction and high-temperature action, and cracks and partial peeling of the copper alloy layer are easy to generate under the repeated circulation action of alternating stress, so that the wear resistance of the copper alloy serving as the antifriction layer is reduced. Various friction pair components of the plunger pump assembly are used for bearing pressure and resisting impact, are structural components and functional components, and a copper-nodular cast iron interface of the bimetallic friction pair component has certain bonding strength, and also ensures that a copper alloy prepared on the surface of nodular cast iron is used as a wear-resistant layer and an antifriction layer, and has the advantages of fatigue resistance, occlusion resistance, wear reduction, good heat conductivity and difficult friction adhesion when the working temperature reaches 300 ℃. In the prior art, the interface bonding strength between copper and nodular cast iron or copper and steel of a bimetallic friction pair component is mostly emphasized, and the performance of a copper alloy as a wear-resistant layer and an antifriction layer and the influence of thermal effect on the performance of the copper alloy in the manufacturing process are ignored. Therefore, how to prepare the ductile cast iron bimetal hydraulic component by adopting a simple and effective process and method prolongs the service life of the hydraulic component, and is the irremovable responsibility and task of scientific researchers.
Disclosure of Invention
The invention aims to provide a copper-nodular cast iron bimetal hydraulic wear-resistant part and a preparation method thereof.
The core of the copper-nodular cast iron bimetal hydraulic wear-resistant component and the preparation method thereof is as follows: firstly, the copper alloy is used as a wear-resistant layer and an antifriction layer; the second is copper-nodular cast iron connection technology. The copper alloy consists of two parts, wherein one part is the copper alloy containing silicon and titanium which can be combined with nodular cast iron compactly as an intermediate layer, and the other part is the manganese brass alloy as a wear-resistant layer and an antifriction layer.
The copper-nodular cast iron bimetal hydraulic wear-resistant part and the preparation method thereof can also be used for repairing the wear surface of a copper-nodular cast iron bimetal friction pair part and recovering the size and the function of the part, and the formed wear-resistant layer alloy has higher bonding strength with a matrix and more importantly ensures that the wear resistance and the heat conductivity of the wear-resistant layer alloy cannot be reduced.
The above object of the present invention is achieved by:
a first layer is a copper alloy with a middle layer containing microelements such as silicon and titanium, and the components of the copper alloy in percentage by mass (Wt/%): zinc (Zn): 0.2 to 3.5%, silicon (Si): 0.2-5%, nickel (Ni): 0.1 to 3.5%, titanium (Ti): 0.2-2.5%, lithium (Li): 1-5% and the balance copper (Cu); the second layer is a manganese brass alloy of a wear-resistant layer and an antifriction layer, and comprises the following components in percentage by mass (Wt%): copper (Cu): 35-45, silicon (Si): 0.5-2.5, zinc (Zn): 45-75, nickel (Ni): 0.2-1.0 and manganese (Mn)0.2-1.0, iron (Fe): and (4) the balance.
Further, the intermediate layer and the wear-resistant layer are heated to a molten state by adopting high-frequency induction graphite radiation, and are protected by high-temperature molten salt in the melting process, and are prepared into the strip-shaped copper alloy by a melting and strip-spinning machine.
Further, the molten salt composition comprises the following components in percentage by mass: sodium chloride NaCl: 25 to 30 portions of calcium chloride CdCl2: 40-50 parts of calcium fluoride CaF2:20-25。
The invention relates to a preparation method of a copper-nodular cast iron bimetal hydraulic wear-resistant part, which comprises the following process steps:
firstly, determining the copper alloy components for manufacturing the intermediate layer and the wear-resistant layer of the copper-nodular cast iron bimetal hydraulic wear-resistant component. The copper alloy of the intermediate layer and the wear-resistant layer is prepared by uniformly mixing and smelting metals with the purity of 99.99% according to design components, heating (graphite radiation) to a molten state by using a high-frequency induction furnace, protecting by using high-temperature molten salt in the smelting process, and preparing into the strip-shaped copper alloy by using a smelting strip-spinning machine. The copper alloy composition of the middle layer is calculated by the mass percentage (Wt%): zinc (Zn): 0.2 to 3.5%, silicon (Si): 0.2-5%, nickel (Ni): 0.1 to 3.5%, titanium (Ti): 0.2-2.5%, lithium (Li): 1-5% and the balance copper (Cu); the manganese brass alloy components of the wear-resistant layer and the antifriction layer are calculated by mass percentage (Wt%): copper (Cu): 35-45, silicon (Si): 0.5-2.5, zinc (Zn): 45-75, nickel (Ni): 0.2-1.0 and manganese (Mn)0.2-1.0, iron (Fe): and (4) the balance. The molten salt composition is as follows by mass percent (Wt%): 25-30 parts of sodium chloride (NaCl) and calcium chloride (CdCl)2)40-50 parts of calcium fluoride (CaF)2)20-25。
And secondly, mechanically and chemically treating the surface of the nodular cast iron to remove oil stains and oxides.
Thirdly, depositing an intermediate layer on the surface of the nodular cast iron by adopting an electric spark deposition method, wherein the electric spark deposition process parameters are that the voltage is 55-75V, the frequency is 225-242HZ, the thickness of the deposited layer is 5-25 mu m, and the intermediate layer alloy and the surface of the nodular cast iron form compact metallurgical bonding;
fourthly, preparing the wear-resistant manganese brass alloy on the surface of the intermediate layer alloy by adopting a cold welding method, wherein the cold welding process parameters are as follows: the power is 50-80W, the welding time is 25-80s, and the thickness of the wear-resistant layer alloy is 8-25 mm until the wear-resistant layer and the antifriction layer are formed by solidification.
And fifthly, carrying out heat treatment on the ductile cast iron bimetal under the protection of argon, keeping the temperature for 0-30 min at 200-400 ℃, cooling to room temperature along with a furnace, and treating the surface by a mechanical method.
The interlayer copper alloy in the copper-nodular cast iron bimetal hydraulic component contains zinc (Zn), silicon (Si), nickel (Ni), titanium (Ti), lithium (Li) and copper (Cu), wherein the silicon (Si) and graphite in the nodular cast iron have better bonding performance, so that more compact interface connection can be formed, and the generation of interface defects is reduced; titanium (Ti) as an active element can promote interfacial reaction; the element lithium (Li) can lower the melting temperature of the alloy and improve the wetting rate. The manganese brass alloy of the wear-resistant layer has larger difference in physical, chemical and mechanical properties with the nodular cast iron, and the manganese brass and the nodular cast iron are directly heated and welded, so that a large number of hole defects are formed on an interface, and the interface connection strength is lower. The invention adopts a cold welding method to perform electric and thermal coupling, and instantly heats the surface of the metallized nodular cast iron with the preset intermediate layer to quickly form metallurgical bonding of an interface, thereby avoiding the carburization phenomenon of the nodular cast iron and the softening of copper alloy caused by overlong high-temperature retention time, and the prepared copper-nodular cast iron bimetallic material has better wear resistance and heat conductivity.
Compared with the prior art, the invention has the beneficial effects that:
according to the copper-nodular cast iron bimetal hydraulic wear-resistant part and the preparation method thereof, the copper alloy containing silicon and titanium is used as the intermediate layer material to form a well-combined non-ferrous metallized interface on the surface of nodular cast iron, so that the bonding strength of the copper alloy used as the wear-resistant layer and the anti-friction layer and the nodular cast iron is improved, meanwhile, the cold welding forming technology is adopted to avoid the influence of the thermal process on the performance of the copper alloy, and the formed copper alloy wear-resistant layer and the anti-friction layer have good wear resistance and thermal conductivity.
Drawings
FIG. 1 illustrates the interface of a copper-ductile iron bi-metal interface after heat treatment;
FIG. 2 is a graph of the coefficient of friction of a wear layer of copper alloy;
fig. 3 is a heat conduction test curve of the copper alloy wear layer.
Detailed Description
The process according to the invention is further illustrated in detail by the examples given below in conjunction with the figures (FIGS. 1, 2 and 3).
Fig. 1 is a photomicrograph of the copper-ductile iron interface of the present invention.
FIG. 2 is a graph of the coefficient of friction of the copper alloy of the wear layer and friction reducing layer of the present invention.
FIG. 3 is a graph of the thermal conductivity of the wear layer and friction reducing layer copper alloy of the present invention.
The invention relates to a copper-nodular cast iron bimetal hydraulic wear-resistant component and a preparation method thereof, which comprises the following process steps:
firstly, determining the copper alloy components for manufacturing the intermediate layer and the wear-resistant layer of the copper-nodular cast iron bimetal hydraulic wear-resistant component. The copper alloy of the intermediate layer and the wear-resistant layer is prepared by uniformly mixing and smelting metals with the purity of 99.99% according to design components, heating to a molten state by adopting a high-frequency induction furnace (graphite radiation), protecting by adopting high-temperature molten salt in the smelting process, and preparing into the strip-shaped copper alloy by using a smelting strip-spinning machine. The copper alloy composition of the middle layer is calculated by the mass percentage (Wt%): zinc (Zn): 0.2 to 3.5%, silicon (Si): 0.2-5%, nickel (Ni): 0.1 to 3.5%, titanium (Ti): 0.2-2.5%, lithium (Li): 1-5% and the balance copper (Cu); the manganese brass alloy components of the wear-resistant layer and the antifriction layer are calculated by mass percentage (Wt%): copper (Cu): 35-45, silicon (Si): 0.5-2.5, zinc (Zn): 45-75, nickel (Ni): 0.2-1.0 and manganese (Mn)0.2-1.0, iron (Fe): and (4) the balance. The molten salt composition is as follows by mass percent (Wt%): 25-30 parts of sodium chloride (NaCl) and calcium chloride (CdCl)2)40-50 parts of calcium fluoride (CaF)2)20-25。
And secondly, mechanically and chemically treating the surface of the nodular cast iron to remove oil stains and oxides.
Thirdly, depositing an intermediate layer on the surface of the nodular cast iron by adopting an electric spark deposition method, wherein the electric spark deposition process parameters are that the voltage is 55-75V, the frequency is 225-242HZ, the thickness of the deposited layer is 5-25 mu m, and the intermediate layer alloy and the surface of the nodular cast iron form compact metallurgical bonding;
fourthly, preparing the wear-resistant manganese brass alloy on the surface of the intermediate layer alloy by adopting a cold welding method, wherein the cold welding process parameters are as follows: the power is 50-80W, the welding time is 25-80s, and the thickness of the wear-resistant layer alloy is 8-25 mm until the wear-resistant layer alloy is solidified to form the wear-resistant coating.
And fifthly, carrying out heat treatment on the ductile cast iron bimetal under the protection of argon, keeping the temperature for 0-30 min at 200-400 ℃, cooling to room temperature along with a furnace, and treating the surface by a mechanical method.
The copper-nodular cast iron bimetal hydraulic wear-resistant component and the preparation method thereof provided by the invention have the following technical indexes that the preparation is carried out according to the process steps and the components:
(1) the microhardness of the copper alloy wear-resistant layer on the surface of the nodular cast iron is 300-330 HV;
(2) according to the GB/T3651-2008 metal high-temperature heat conductivity coefficient determination method, the room-temperature heat conductivity coefficient of the nodular cast iron surface wear-resistant layer copper alloy is 110-118W/(mK), and the 150 ℃ heat conductivity coefficient is 119-125W/(mK);
(3) according to a friction coefficient test method of a YB/T4286-2012 metal material thin plate and a thin strip, the lubricating oil friction coefficient of the copper alloy wear-resistant layer on the surface of the nodular cast iron is 0.101-0.105.
All the following embodiments are obtained by adopting the components, the process steps, the process and the parameters.
Examples are shown in tables 1 and 2 below:
table 1 intermediate and wear resistant layers copper alloy composition (wt.%)
Table 2 Heat treatment Process and Properties of wear-resistant layer of copper alloy
The embodiments of the invention have been disclosed above, but are not limited to the applications listed in the description and the embodiments. It can be applied to all kinds of fields suitable for the present invention. Additional modifications will readily occur to those skilled in the art. It is therefore intended that the invention not be limited to the exact details and illustrations described and illustrated herein, but fall within the scope of the appended claims and equivalents thereof.
Claims (4)
1. The copper-nodular cast iron bimetal hydraulic wear-resistant part is characterized by comprising a base material, an intermediate layer and a wear-resistant layer, wherein the base material comprises nodular cast iron, the intermediate layer comprises a copper alloy, and the components of the intermediate layer are calculated according to the mass percent by weight: zinc Zn: 0.2 to 3.5%, Si: 0.2-5%, Ni: 0.1 to 3.5%, Ti: 0.2 to 2.5%, lithium Li: 1-5% of Cu, and the balance of Cu; the wear-resistant layer is composed of a manganese brass alloy, and comprises the following components in percentage by weight: copper Cu: 35-45, silicon Si: 0.5-2.5, zinc Zn: 45-75, nickel Ni: 0.2-1.0, Mn0.2-1.0, Fe: and (4) the balance.
2. The copper-nodular cast iron bimetal hydraulic wear-resistant component of claim 1, wherein the intermediate layer and the wear-resistant layer are heated to a molten state by high-frequency induction graphite radiation, and the melting process is protected by high-temperature molten salt and is prepared into a strip-shaped copper alloy by a melting and belt-spinning machine.
3. The copper-nodular cast iron bimetal hydraulic wear-resistant component of claim 2, wherein the molten salt comprises the following components in percentage by mass: sodium chloride NaCl: 25 to 30 portions of calcium chloride CdCl2: 40-50 parts of calcium fluoride CaF2:20-25。
4. The method for preparing the copper-nodular cast iron bimetal hydraulic wear-resistant part as claimed in any one of claims 1 to 3, wherein a dense continuous wear-resistant copper alloy layer is formed on the surface of the nodular cast iron by combining an electric spark deposition method and a cold welding process by adopting a double heat source process, and the method comprises the following specific steps of:
firstly, determining copper alloy components for manufacturing a middle layer and a wear-resistant layer of a copper-nodular cast iron bimetal hydraulic wear-resistant component;
secondly, mechanically treating the surface of the nodular cast iron to remove oil stains and oxides;
thirdly, depositing a wear-resistant alloy intermediate layer on the surface of the nodular cast iron by adopting an electric spark deposition method, wherein the electric spark deposition process parameters are that the voltage is 55-75V, the frequency is 225-242Hz, the thickness of the deposited layer is 5-25 mu m, and the intermediate layer alloy and the surface of the nodular cast iron form compact metallurgical bonding;
fourthly, preparing the wear-resistant manganese brass alloy on the surface of the intermediate layer alloy by adopting a cold welding method, wherein the cold welding process parameters are as follows: the power is 50-80W, the welding time is 25-80s, and the thickness of the wear-resistant alloy layer is 8-25 mm until the wear-resistant alloy layer is solidified to form a wear-resistant coating;
and fifthly, carrying out heat treatment on the ductile cast iron bimetal under the protection of argon, keeping the temperature for 0-30 min at 200-400 ℃, cooling to room temperature along with a furnace, and treating the surface by a mechanical method.
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CN115368951A (en) * | 2022-08-08 | 2022-11-22 | 广州诺拜因化工有限公司 | High-temperature-resistant copper-based anti-tightening agent |
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