CN112593156A - 一种新氮化钢在制造柴油机柱塞偶件中的应用 - Google Patents

一种新氮化钢在制造柴油机柱塞偶件中的应用 Download PDF

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CN112593156A
CN112593156A CN202011425182.9A CN202011425182A CN112593156A CN 112593156 A CN112593156 A CN 112593156A CN 202011425182 A CN202011425182 A CN 202011425182A CN 112593156 A CN112593156 A CN 112593156A
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workpiece
plunger
nitriding
furnace
nitrided steel
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杨静
陈茂涛
王永坤
薛建
何晓飞
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Chongqing Hongjiang Machinery Co Ltd
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Abstract

本发明涉及一种新氮化钢在制造柴油机柱塞偶件中的应用，包括以下步骤：第一步，氮化前预处理；第二步，工件氮化前清理；第三步，表面氮化处理；第四步，工件磨削加工；第五步，工件真空镀膜。本发明采用新氮化钢制作的柴油机柱塞偶件，具备含铝氮化钢和无铝氮化钢的优点，规避含铝氮化钢和无铝氮化钢的的缺点，经复合热处理后，能够提高低速柴油机柱塞泵的使用性能，减少排放。

Description

一种新氮化钢在制造柴油机柱塞偶件中的应用
技术领域
本发明涉及柴油机构件，具体涉及一种新氮化钢在制造柴油机柱塞偶件中的应用。特别是用于船用低速柴油机柱塞偶件的热处理。
背景技术
目前，生产的瓦锡兰、苏尔寿和B&W系列低速机柱塞偶件及部分中速机及调速器类零件，大都采用38CrMoAl和32Cr3Mo1V氮化钢制作。38CrMoAl是一种含铝渗氮钢，经过氮化处理后，可以获得很高的表面硬度和良好的耐磨性，但有过热敏感性、渗氮层表面脆性较大、脉状氮化物较差、抗高频冲击的能力较低，后续加工容易出现磨削裂纹；大直径的柱塞和柱塞套调质时淬不透，易产生游离铁素体，对产品使用性能造成不利影响。32Cr3Mo1V氮化钢属于一种无铝渗氮钢，相对于38CrMoAl来说，淬透性和氮化后渗氮层脆性有明显改善，但是，其氮化后的硬度较低，以致抗疲劳性能、耐磨性较低。另外，上述两种氮化钢的热处理工艺参数相差较大，无法混炉生产，热加工成本较高。因此，需要寻求一种高淬透性、高氮化表面硬度和低脆性的氮化钢来替代上述两种渗氮钢，并通过适当的热处理工艺方法提高柱塞偶件的综合使用性能，为市场提供性价比更高的产品。
CN102443740A公开了“一种合金氮化钢”，其各化学元素的质量百分比为：碳：0.30~0.36wt%；硅：0.60~0.80wt%；锰：0.60~0.90wt%；铬：2.90~3.40wt%；钼：0.40~0.60wt%；钒：0.15~0.25wt%；铌：0.02~0.06wt%；硫：≤0.015wt%；磷：≤0.020wt%；铜：≤0.15wt%；镍：≤0.15wt%；余量为Fe和其他不可避免的杂质。该合金氮化钢淬透性较高；耐热性好；经热处理后应当具有良好的强韧性；氮化后，其渗层深度、心部硬度均高于现有含铝渗氮钢。
该专利文献公开的一种合金氮化钢的热处理性能和热处理后的机械性能不失为制造柴油机柱塞偶件一种合适的选择。
发明内容
本发明的目的在于提供一种新氮化钢在制造柴油机柱塞偶件中的应用，其采用新氮化钢制作的柴油机柱塞偶件，具备含铝氮化钢和无铝氮化钢的优点，规避含铝氮化钢和无铝氮化钢的的缺点，经复合热处理后，能够提高低速柴油机柱塞泵的使用性能，减少排放。
本发明所述的一种新氮化钢在制造柴油机柱塞偶件中的应用，其特征是，选择制造柴油机柱塞偶件的新氮化钢的化学成分为：碳，0.33wt%；硅，0.63wt%；锰，0.73wt%；铬，3.35wt%；钼，0.59wt%；钒，0.28wt%；磷，0.0065wt%；硫，0.001wt%；余量为Fe和其他不可避免的杂质，是一种无铝渗氮钢；包括以下步骤：
第一步，氮化前预处理；将圆钢进行粗加工，形成柱塞偶件毛坯，即工件，并对工件进行调质处理，调质处理程序：先将工件装入空气加热炉中，装炉工件间隔间距≥20mm；再加热升温，使炉温升至920±5℃，保温215±10分钟，使工件充分奥氏体化；然后，工件出炉淬入油中，油温为40-80℃，搅拌30至40分钟，冷透取出；最后，在空气回火炉中进行回火处理，回火温度为670±10℃，保温300±10分钟，保温结束出炉空冷；
第二步，工件氮化前清理；先将调质处理后的工件单边至少加工2mm，去除氧化皮，并机加工至氮化前的工艺尺寸；再采用水基清洗剂和溶剂型清洗剂相结合的方式清洗，用水基清洗剂抹洗干净工件表面，并用清水冲洗干净清洗剂泡沫，之后立即用压缩空气吹干，再放入溶剂型清洗剂抹洗干净工件，最后，用压缩空气吹干工件，准备装炉；
第三步，表面氮化处理；对工件进行氮化处理，氮化处理程序：先将清理后的工件装入气体氮化炉中，竖直放置工件，工件间隔距离≥20mm；再通入氨气排出炉内空气，排气完毕加热升温至350±5℃，预氧化两个小时，之后升温至500±5℃通入氨气进行氮化；
第四步，工件磨削加工；将表面氮化处理后的工件单边磨削≦0.05mm，粗糙度不超过0.1，并清洗干净工件，准备镀膜；
第五步，工件真空镀膜；采用PCVD沉积镀膜法进行处理，涂层材料为CrN+a-C：H，在工件表面沉积CrN+a-C：H涂层，涂层时温度控制在200±5℃以内。
进一步，所述柴油机柱塞偶件由柱塞套和与其配合的柱塞构成。
进一步，在第一步，氮化前预处理的淬火剂为好富顿G油。
进一步，第三步，表面氮化处理；在500±5℃氮化时，采用对氨气分解率分段进行控制：第一段分解率按18-25%控制，时间30±1小时，第二段按25-35%控制，时间30±1小时，氮化结束降温过程中继续通入氨气保持炉内正压，待降温至100℃以下出炉。
本发明的有益效果：
由于采用新氮化钢制造柴油机柱塞偶件，使柱塞芯部机械性能、氮化后的硬度、脆性，金相组织等都优于32Cr3Mo1V和38CrMoA氮化钢l，并且综合工艺成本较低，可以替代上述传统氮化钢；由于经过PCVD沉积镀膜处理后，使用性能更佳，对减小排放、延长使用寿命都有明显优势。
附图说明
图1是柴油机柱塞偶件的结构示意图。
具体实施方式
本发明所述的一种新氮化钢在制造柴油机柱塞偶件中的应用，其特征是，选择制造柴油机柱塞偶件的新氮化钢的化学成分为：碳，0.33wt%；硅，0.63wt%；锰，0.73wt%；铬，3.35wt%；钼，0.59wt%；钒，0.28wt%；磷，0.0065wt%；硫，0.001wt%；余量为Fe和其他不可避免的杂质，是一种无铝渗氮钢；包括以下步骤：
第一步，氮化前预处理；将φ85×305mm的圆钢进行粗加工，形成柱塞偶件毛坯，即工件，并对工件进行调质处理，以保证工件的芯部具有较好的综合力学性能；
调质处理程序：先将工件装入空气加热炉中，装炉工件间隔间距≥20mm；再加热升温，使炉温升至920±5℃，保温215±10分钟，使工件充分奥氏体化；然后，工件出炉淬入油中，淬火剂选用好富顿G油，油温为40-80℃，搅拌30至40分钟，冷透取出；最后，在空气回火炉中进行回火处理，回火温度为670±10℃，保温300±10分钟，保温结束出炉空冷；
工件调质处理后，每炉抽1件工件检测芯部金相组织和硬度，芯部必须是良好的回火索氏体，硬度为28-32HRC为合格；
第二步，工件氮化前清理；先将调质处理后的工件单边至少加工2mm，去除氧化皮，并机加工至氮化前的工艺尺寸；再采用水基清洗剂和溶剂型清洗剂相结合的方式清洗，用水基清洗剂抹洗干净工件表面，并用清水冲洗干净清洗剂泡沫，之后立即用压缩空气吹干，再放入溶剂型清洗剂抹洗干净工件，最后，用压缩空气吹干工件，准备装炉；
第三步，表面氮化处理；对工件进行氮化处理，以保证工件表面具有高的硬度、高的耐磨性能、高的抗疲劳和良好的抗咬合性能；
氮化处理程序：先将清理后的工件装入气体氮化炉中，竖直放置工件，工件间隔距离≥20mm；再通入氨气排出炉内空气，约1-2小时，排气完毕加热升温至350±5℃，预氧化1.5-2小时，之后升温至500±5℃进行氮化，升温过程中仍要通入氨气排气；在500℃氮化时，采用对氨气分解率分段进行控制：第一段分解率按18-25%控制，时间30±1小时，第二段按25-35%控制，时间30±1小时，氮化结束降温过程中继续通入氨气保持炉内正压，待降温至100℃以下出炉；整个操作过程中不能直接用手触摸工件，应戴上橡胶手套进行操作，防止工件生锈或出现手印。
工件表面氮化处理后，每炉抽1件工件检测氮化层深度、金相组织及距离表面0.05mm处的硬度，并检测表面脆性；氮化层深≥0.45mm（400HV处），脆性1级、脉状氮化物2级、梯度0.05mm处硬度≥900HV。
第四步，工件磨削加工；将表面氮化处理后的工件单边磨削≦0.05mm，粗糙度不超过0.1，并清洗干净工件，准备镀膜；
第五步，工件真空镀膜；采用PCVD沉积镀膜法进行处理，涂层材料为CrN+a-C：H，在工件表面沉积CrN+a-C：H涂层，涂层时温度控制在200℃以内。
工件真空镀膜后，抽样检测涂层厚度和结合力；要求涂层厚度3-5μm，镀层结合力HF1-HF2。
参见图1，所述柴油机柱塞偶件由柱塞套1和与其配合的柱塞2构成。
采用所述无铝渗氮钢制造柴油机柱塞偶件，淬透性好（φ75样棒可以完全淬透，芯部和表面硬度都可达HRC52）、综合力学性能好、晶粒度细小（达8级以上）、氮化后脉状氮化物状态好（在2级以内），脆性好（达1级），这几项性能比38CrMoAl好，和32Cr3Mo1V相当，氮化后硬度比38CrMoAl低，但比32Cr3Mo1V高（可达900HV以上，最高达945HV1）；
工件检测：用洛氏硬度计检测外圆硬度和镀层结合力，用金相显微镜检测氮化层组织和芯部金相组织，用偏摆仪检查跳动量，用维氏硬度计检测硬度梯度和脆性。
选择所述新氮化钢制造柴油机柱塞偶件，经上述方法处理后的柱塞表面硬度可达900HV以上，外圆跳动控制在0.02mm以内，脉状氮化物1级，脆性1级，芯部硬度30HRC，机械性能为Rm=830N/mm2; Re=676 N/mm2，A(%)=22.2%，Z(%)=61.4%，Kv=232J、249J。
本发明提供的一种新氮化钢在制造柴油机柱塞偶件中的应用，其复合热处理工艺流程及其工艺参数和方法，用于替代传统氮化材料32Cr3Mo1V和38CrMoAl材料柱塞，用于船用低速柴油机柱塞泵，其综合加工成本可以节约1/5以上，使用寿命延长20%以上，排放减少10%以上。

Claims (4)

1.一种新氮化钢在制造柴油机柱塞偶件中的应用，其特征是，选择制造柴油机柱塞偶件的新氮化钢的化学成分为：碳，0.33wt%；硅，0.63wt%；锰，0.73wt%；铬，3.35wt%；钼，0.59wt%；钒，0.28wt%；磷，0.0065wt%；硫，0.001wt%；余量为Fe和其他不可避免的杂质，是一种无铝渗氮钢；包括以下步骤：
第一步，氮化前预处理；将圆钢进行粗加工，形成柱塞偶件毛坯，即工件，并对工件进行调质处理，调质处理程序：先将工件装入空气加热炉中，装炉工件间隔间距≥20mm；再加热升温，使炉温升至920±5℃，保温215±10分钟，使工件充分奥氏体化；然后，工件出炉淬入油中，油温为40-80℃，搅拌30至40分钟，冷透取出；最后，在空气回火炉中进行回火处理，回火温度为670±10℃，保温300±10分钟，保温结束出炉空冷；
第二步，工件氮化前清理；先将调质处理后的工件单边至少加工2mm，去除氧化皮，并机加工至氮化前的工艺尺寸；再采用水基清洗剂和溶剂型清洗剂相结合的方式清洗，用水基清洗剂抹洗干净工件表面，并用清水冲洗干净清洗剂泡沫，之后立即用压缩空气吹干，再放入溶剂型清洗剂抹洗干净工件，最后，用压缩空气吹干工件，准备装炉；
第三步，表面氮化处理；对工件进行氮化处理，氮化处理程序：先将清理后的工件装入气体氮化炉中，竖直放置工件，工件间隔距离≥20mm；工件随炉加热升温至350±5℃，预氧化一个小时，之后通氨排尽炉内空气，确保在410±5℃前排尽炉内空气，升温至500±5℃持续通入氨气进行氮化；
第四步，工件磨削加工；将表面氮化处理后的工件单边磨削≤0.05mm，粗糙度不超过0.1，并清洗干净工件，准备镀膜；
第五步，工件真空镀膜；采用PCVD沉积镀膜法进行处理，涂层材料为CrN+a-C：H，在工件表面沉积CrN+a-C：H涂层，涂层时温度控制在200±5℃以内。
2.根据权利要求1所述的新氮化钢在制造柴油机柱塞偶件中的应用，其特征是：所述柴油机柱塞偶件由柱塞套（1）和与其配合的柱塞（2）构成。
3.根据权利要求1或2所述的新氮化钢在制造柴油机柱塞偶件中的应用，其特征是：在第一步，氮化前预处理的淬火剂为好富顿G油。
4.根据权利要求1或2所述的新氮化钢在制造柴油机柱塞偶件中的应用，其特征是：第三步，表面氮化处理；在500±5℃氮化时，采用对氨气分解率分段进行控制：第一段分解率按18-25%控制，时间30±1小时，第二段按25-35%控制，时间30±1小时，氮化结束降温过程中继续通入氨气保持炉内正压，待降温至100℃以下出炉。
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