CN113238020A - Method for rapidly researching and developing novel electric contact material - Google Patents
Method for rapidly researching and developing novel electric contact material Download PDFInfo
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Abstract
The invention discloses a method for rapidly researching and developing a novel sliding electric contact experimental material, which is suitable for rapidly researching and developing a multi-element alloy material. The method comprises the following steps: 1) the gradient solidification high-flux experiment accelerates the screening of the optimal components of the novel electric contact material alloy; 2) the fractional melting solidification high-flux preparation technology optimizes the high-efficiency preparation technology of the alloy ingot blank; 3) optimizing alloy heat treatment and plastic deformation processing technologies based on a gradient temperature high-flux homogenization heat treatment technology and a high-flux plastic deformation technology; 4) and evaluating and verifying the comprehensive performance of the silver-based electric contact material. In the process of material component design and preparation processing technology screening, the idea of material genetic engineering is applied, the high-throughput experiment technology is used for quickly realizing the optimal component screening of the multi-component alloy and the efficient and low-cost preparation of the target component, and the efficiency of experiment and research is greatly improved.
Description
Technical Field
The invention belongs to the technical field of sliding electric contact materials and material genetic engineering, and particularly relates to a method for quickly researching and developing a novel electric contact material, which is suitable for quickly researching and developing a multi-element alloy electric contact material and is beneficial to component optimization design and efficient and low-cost preparation of the electric contact material.
Background
The DC micromotor is an indispensable electronic device in the manufacturing industries of audio-visual electronic equipment, office automation equipment, communication equipment, automobiles and household appliances. Most direct current micromotors adopt sliding contact between a three-pole commutator and an electric brush to realize power transmission and maintain the operation of the motor. Therefore, the working conditions of the commutator and the brushes have a significant influence on the stability and the service life of the motor. The commutator is one of the core elements of the direct current micromotor, and is generally prepared by a cheap and noble composite method, wherein the base layer metal is generally cheap metal Cu or Cu alloy and plays a structural role, and the surface layer metal is Ag-based alloy and plays a conductive and wear-resistant role. In the early stage, Cd-containing alloys such as AgCd, AgCuCd and the like are mainly used, with the technical progress and the soundness of environmental regulations, particularly with the forced implementation of RoHS instruction in European Union, the Cd-containing alloys exit the market, and various novel environment-friendly commutator materials are developed, wherein the commonly used materials comprise series of AgCu, AgCuNi, AgCuZnNi, AgCuRE, AgMgNi, AgSnO2, AgZnO and the like. Because the alloys have good electrical conductivity, low contact resistance, corrosion resistance, oxidation resistance, wear resistance, arc damage resistance and other excellent performances, the alloys replace AgCd alloy materials containing Cd poison in most micro-motor products. However, the alloys still have the problems of short service life and poor stability in the service process. In recent years, with the rapid development of the micro-motor manufacturing industry, the performance indexes of the micro-motor in the aspects of miniaturization, low noise, stable operation speed, long service life and the like are required to be higher and higher, and in order to improve the reliability and the service life of a commutator material, the wear resistance of the material is further improved, so that the development of a commutator material with high wear resistance and long service life is imperative. At present, a novel sliding type electric contact material is developed mainly by introducing a new strengthening component and an alloying method for changing the content of an added element. However, the novel development alloy is a quaternary alloy, a quinary alloy or even other multi-element alloys, and the novel development alloy is designed and developed in the face of the universality problems of large research and development workload and the like caused by complex components and structures.
Despite the ability of existing experimental techniques to produce and produce structures with a variety of functional properties, even non-ground high energy structures. However, the method of experimentally finding and optimally designing functional materials is generally a "trial and error approach". The space of the material determined by the factors such as components, structures, preparation and processing conditions and the like is huge. The new electric contact material is searched in a huge material space by a trial-and-error method, and the problems of long development period, high cost and the like are faced. In order to improve the efficiency of development and synthesis of functional materials and meet the market demand, developed countries and developing countries, including the united states, have proposed "material genomes" plans in succession, aiming at experimental development and synthesis of functional materials under theoretical guidance. Therefore, the novel electric contact material is developed based on a high-throughput experimental technology in a material genome, so that a more reliable material can be obtained with higher efficiency and low cost. The invention provides a high-throughput gradient solidification method for preparing a component gradient material, and a large amount of high-quality data with good identity are obtained. And the method can solve the problems of complex preparation work in the early stage, incapability of plastic processing and the like when the gradient component materials are prepared by a diffusion multicomponent junction method, a film method and the like.
In addition, in the research at home and abroad, the high-throughput test mainly realizes the preparation of alloy multi-components, but the screening of process parameters in the solidification preparation process and the optimization of heat treatment and plastic processing processes are less involved. The final performance of the alloy is determined by multiple factors such as components, structures, preparation and processing conditions and the like, and the optimization screening of the heat treatment conditions and the preparation and processing conditions is the same as the component design, so that the problems of long screening period, high design cost and the like exist.
Disclosure of Invention
The technical problem to be solved by the invention is to solve the problems of high cost, huge workload and the like existing in the process of researching and developing a novel multi-element electric contact alloy material at present, and to provide the purposes of greatly promoting research and development speed, saving experiment cost, improving new material searching capacity and the like by applying the thought of material genetic engineering and adopting a gradient solidification high-throughput experimental method in the process of material component design and preparation processing technology screening. Meanwhile, the invention adopts a fractional-melting solidification high-flux preparation method, a gradient temperature homogenization heat treatment method and a high-flux plastic processing method, which are respectively used for the screening of the optimal process parameters of the multi-element alloy ingot, the screening of homogenization heat treatment conditions and the optimization of the plastic deformation process, and finally, the purposes of realizing the design of the ideal component alloy and the optimization of the preparation processing process with high efficiency and low cost are achieved.
In order to achieve the above purpose, the invention provides the following technical scheme:
the invention relates to a high-flux preparation method of a sliding electric contact experimental material with component gradient distribution, which comprises the following specific steps:
s1-1, respectively weighing and proportioning according to the required component proportion, and obtaining the gradient sample with continuously changed components by adopting a high-flux gradient component directional solidification preparation method. The upper die contains solute alloy, and the lower die contains base alloy with equal concentration. The high-frequency induction heating is adopted, the flow of the solute alloy melt is controlled by using a stopper rod, the concentration of the solute in the metal liquid in the lower die is controlled, and finally a gradient alloy sample ingot with gradient change of components is obtained;
s1-2, the cast sample is continuously heat treated and processed. The time of the homogenization heat treatment is at least 4 hours or more to ensure the uniformity of the composition, structure and properties. Carrying out cold drawing processing after homogenizing heat treatment, controlling the single-pass deformation within 4-15%, controlling the total deformation to be more than 50%, and not annealing in the middle;
s1-3, testing the performances and components of the gradient alloy sample in the casting state, the heat treatment state and the processing state, such as hardness, resistivity and the like, and screening out the optimal alloy component proportion according to the performance requirements (when the sliding electric contact multi-element alloy material is subjected to component design, in order to simplify the test and highlight the performance comparison in the casting state, the processing state and the heat treatment state, the electrical conductivity and the mechanical property of the material are mainly considered, and the material with lower contact resistance and higher strength (hardness) is expected to be obtained).
S2-1 adopts a fractional melting solidification high-flux preparation method to prepare the gradient structure alloy. Firstly, alloy samples with the optimal component ratio are subjected to induction heating smelting, a section of solidified ingot is firstly pulled out through a traction rod after the alloy samples are completely molten, then a traction device is suspended, the traction speed is changed, the traction device is started again after heat preservation is carried out for a period of time, another section of ingot with different traction speeds is pulled out, the traction is suspended again, and the traction speed is changed again; by analogy, a solidified cast ingot with the same components and different solidified structures is finally formed;
s2-2, representing the alloy structure and performance prepared at different traction speeds, and screening out the optimal traction speed (performance requirements: low resistance and high hardness; structure requirements: few macro-micro defects of ingot casting, uniform structure, less segregation of low-melting-point non-equilibrium phase and dendrite, uniform dispersion distribution of second phase, and remarkable fine-grain strengthening effect and dispersion strengthening effect; the following structure performance requirements are the same and are not repeated);
s2-3, sequentially changing solidification process parameters such as heating temperature, cooling water flow and the like, repeating the operations of the step S2-1 and the step S2-2, obtaining alloy casting blanks under different solidification parameters, and finally screening out the optimal solidification process parameters.
S3-1, preparing the alloy ingot blank with the structure and the performance distributed in a gradient way by adopting a gradient temperature high-flux homogenization heat treatment method. The heating mode is that a single-strand induction coil is adopted for heating, an experimental sample with a proper length traverses the induction coil and is placed in the middle, two ends of the experimental sample are supported by an alumina ceramic wafer with good heat insulation, the induction heating power is slowly increased, the temperature of the sample at the position of the induction coil reaches a set temperature, then the heating power is kept unchanged, the middle position of the sample is locally heated, the temperature is gradually reduced from the middle position to the two ends through heat transfer, and therefore the continuous change of the internal temperature of the sample is realized, and different parts of the same sample are equivalently subjected to heat treatment at different temperatures in the same time through heating for a certain time. The temperature is measured by an infrared thermometer, and the temperature value is obtained and recorded by moving the induction coil to two ends for a fixed distance each time by taking the position of the induction coil as a center.
S3-2, the alloy structure and the mechanical property at different positions are characterized, and the optimal homogenization heat treatment condition is screened according to the structure and the performance requirements.
And (3) after the treatment of the optimal homogenization heat treatment condition of S4-1, preparing the alloy with different deformation amounts by adopting a high-flux plastic deformation method. Firstly, machining the alloy after the homogenization heat treatment to prepare a stepped, wedge-shaped or conical gradient sample;
s4-2, rolling or drawing the gradient-shaped alloy sample to obtain a high-flux experimental sample with the deformation continuously changing from 20-85%. The alloy structure and mechanical properties of different deformation quantities are characterized, the optimal alloy deformation quantity is screened out according to the structure and performance requirements, and the alloy plastic deformation process is optimized.
S5-1, on the existing electric contact performance characterization equipment, evaluating the service performance (such as contact resistance, abrasion loss, electric noise during current-carrying sliding, temperature rise and the like) of the sliding electric contact of the prepared ideal alloy test group;
s5-2 is compared with the existing silver-based sliding electric contact material in performance, and finally, a novel electric contact material (such as a silver-based electric contact material) meeting the design requirement is screened out.
The invention has the advantages that:
(1) by adopting a gradient solidification high-throughput experimental method, the research and development speed can be greatly promoted, the experimental cost is saved, and the new material searching capability is improved;
(2) the fractional melting solidification high-flux preparation method, the gradient temperature homogenization heat treatment method and the high-flux plastic processing method are provided for optimizing the preparation and processing technology, and the experimental amount, the research and development period and the cost of screening the optimal technological conditions in the research and development process of the novel sliding friction material can be obviously reduced.
The invention has the beneficial effects that:
in view of the thought of high-throughput test, compared with the prior art, the method can finally realize the component optimization design and the efficient low-cost preparation of the novel noble metal material, has important practical requirements for promoting the research and development of the novel electric contact material, and is expected to promote the promotion of the international competitiveness of enterprises and countries in the electric contact material industry.
Experiments show that when a novel sliding electric contact multi-element alloy material is developed, the method for rapidly researching and developing the novel sliding electric contact material can remarkably reduce research and development period and research and development cost, and can accelerate the development of the novel sliding electric contact material and the industrial application of the novel sliding electric contact material in devices such as micro motors, precise electronic instruments and the like. Meanwhile, the method has important scientific demonstration significance for the research and development of new multi-element alloy materials in other industries.
Drawings
Fig. 1 is a flow chart of a preparation process for rapidly developing a novel sliding electrical contact material according to the present invention.
FIG. 2 is a schematic diagram of the directional solidification of the gradient components of the present invention.
FIG. 3 is a schematic illustration of the preparation of a tissue gradient sample according to the present invention.
FIG. 4 is a schematic view of the gradient temperature high flux homogenization heat treatment apparatus of the present invention.
FIG. 5 is a schematic diagram of the high throughput preparation of samples of different deformation amounts according to the present invention.
Detailed Description
The preparation process flow chart of the invention for rapidly developing the novel sliding electric contact material is shown in figure 1, and the specific process steps comprise the steps of preparing a gradient component material by a gradient directional solidification method to obtain an optimal alloy component, optimizing the alloy ingot blank solidification preparation process by a fractional melting solidification high-flux preparation method, optimizing an alloy heat treatment process by a gradient temperature high-flux homogenization heat treatment method, optimizing an alloy plastic deformation processing process by a high-flux plastic deformation method, and evaluating and verifying the comprehensive performance of the silver-based electric contact material.
The invention is further illustrated by the following specific examples.
Example 1: Ag-Cu-Ni-V sliding electric contact material
S1-1, silver with the purity of 99.99%, oxygen-free copper, nickel and vanadium are used as raw materials, an upper die alloy is Ag-Cu-Ni-V solute alloy (the components and the mass percentages are Ag, 90.9%, Cu, 6%, Ni, 3%, V, 0.1%; and the like), and a lower die is Ag-Cu-Ni matrix alloy with the same concentration (the components and the mass percentages are Ag, 91.0%, Cu, 6%, Ni, 3%; and the like);
s1-2, obtaining a gradient sample with continuously changed components by adopting a high-flux gradient component directional solidification preparation method. FIG. 1 is a schematic view of directional solidification of a gradient composition material. The upper die contains solute alloy, and the lower die contains base alloy with equal concentration. The high-frequency induction heating is adopted, the flow of the solute alloy melt is controlled by using the stopper rod, the concentration of the solute in the metal liquid in the lower die is controlled, and finally the alloy ingot with phi 8mm multiplied by 200mm component gradient change is obtained. The adopted solidification process parameters are as follows: the temperature of the upper die is 1400 ℃, the temperature of the lower die is 1100 ℃, after the alloy is completely melted, the temperature is kept for 5min, the drawing is carried out at the blank drawing speed of 0.5mm/s, and the flow rate of cooling water is 300L/h;
s1-3, the cast sample is continuously heat treated and processed. The vacuum homogenization heat treatment conditions are as follows: 600 ℃, 5h, 5X 10-3Pa; after the homogenization heat treatment, cold drawing processing is carried out, and the single-pass deformation is controlledThe total deformation is 60 percent, and annealing is not carried out in the middle;
s1-4, testing the performances and components of the gradient alloy samples in the casting state, the heat treatment state and the processing state, such as hardness, resistivity and the like, at different positions, and screening out the optimal alloy component proportion of Ag-6.13Cu-3.12Ni-0.18V according to the performance requirements (when the sliding electric contact multi-element alloy material is designed, in order to simplify the test and highlight the performance comparison in the casting state, the processing state and the heat treatment state, the electric conductivity and the mechanical property of the material are mainly considered, and the material with lower contact resistance and higher strength (hardness) is expected to be obtained).
S2-1 adopts a fractional melting solidification high-flux preparation method to prepare the gradient structure alloy for the Ag-6.13Cu-3.12Ni-0.18V alloy with the optimal component proportion, and the schematic diagram of the principle is shown in figure 2. Firstly, an alloy sample with the optimal component ratio is smelted by induction heating, and the solidification process parameters are as follows: the drawing speed (0.5-2 mm/s), the heating temperature (1300 ℃) and the cooling water flow rate (300L/h). After the time of complete melting and heat preservation is 5min, firstly drawing a solidified ingot with phi 8mm multiplied by 30mm at the speed of 0.5mm/s through a drawing rod, then suspending a drawing device, changing the drawing speed, after heat preservation is carried out for 20s, starting the drawing device again to draw another section of ingot with different drawing speeds, suspending drawing again, and changing the drawing speed again; by analogy, a solidified cast ingot with the same components and different solidified structures is finally formed;
s2-2, representing the alloy structure and performance prepared at different traction speeds (0.5-2 mm/S), and screening out the optimal traction speed (performance requirements: low resistance and high hardness; structure requirements: few macro-micro defects of cast ingot, uniform structure, less low-melting-point nonequilibrium phase and dendrite segregation, uniform dispersion distribution of second phase, and remarkable fine-grain strengthening effect and dispersion strengthening effect; the following structure performance requirements are the same and are not repeated);
s2-3, sequentially changing solidification process parameters such as heating temperature (1100-1400 ℃) and cooling water flow (200-500L/h), and repeating the operations of S2-1 and S2-2 to obtain alloy casting blanks under different solidification parameters. Finally, the optimum solidification process parameters are selected to be traction speed of 1mm/s, heating temperature of 1200 ℃, and cooling water flow rate of 350L/h.
S3-1, preparing the alloy ingot blank with the structure and the performance distributed in a gradient way by adopting a gradient temperature high-flux homogenization heat treatment method for the Ag-6.13Cu-3.12Ni-0.18V alloy ingot blank prepared by the optimal solidification process parameters. A schematic diagram of a gradient temperature high flux homogenization heat treatment apparatus is shown in FIG. 3. The heating mode is that a single-strand induction coil is adopted for heating, an experimental sample with the size of phi 8mm multiplied by 120mm traverses the induction coil and is placed in the middle of the induction coil, two ends of the experimental sample are supported by alumina ceramic plates with good heat insulation, the induction heating power is slowly increased, the temperature of the sample at the position of the induction coil reaches the set temperature of 750 ℃, then the heating power is kept unchanged, and the heating time is 2 hours. Measuring the temperature by an infrared thermometer, measuring the temperature every 5min after the temperature is stable, wherein the position interval of measuring points is 1cm, moving the fixed distance to the two ends each time by taking the position of the induction coil as the center, obtaining and recording a temperature value, and taking the average value of the measured values as the final temperature of a value taking point;
s3-2, representing the alloy structure and performance at different positions, and screening out the optimal homogenization heat treatment conditions according to the structure and performance requirements as follows: 608-2 h. (for simplicity of the experiment, time is considered herein as a fixed quantity, temperature is used as a variable, and after the optimum temperature is actually determined, the time conditions are changed in a vacuum tube furnace to determine the optimum time, and finally the temperature and time for the optimum homogenization heat treatment can be determined).
S4-1 is processed by the optimal homogenization heat treatment condition, the preparation of the alloy with different deformation amounts is realized by adopting a high-flux plastic deformation method, and the working principle diagram is shown in figure 4. Firstly, machining an alloy with the diameter of 8mm multiplied by 120mm to prepare a conical gradient sample with a thick end and a thin end;
s4-2, drawing the tapered gradient-shaped alloy sample to phi 3mm to obtain a high-flux experimental sample with deformation continuously changing from 20-85%. The alloy structures and the performances of different deformation quantities are characterized, and the optimal alloy deformation quantity is screened according to the structure and the performance requirements as follows: 75 percent.
S5-1, carrying out cold drawing on an alloy ingot blank with phi 8mm to a wire finished product with phi 3mm according to the optimal solidification process parameters (the traction speed is 1mm/S, the heating temperature is 1200 ℃, the cooling water flow is 350L/h), the optimal homogenization heat treatment condition (608-2 h) and the optimal plastic deformation condition (the optimal alloy deformation is 75%) on the Ag-6.13Cu-3.12Ni-0.18V alloy with the optimal alloy components;
s5-2, on the existing electric contact performance characterization equipment, evaluating the sliding electric contact service performance (contact resistance, abrasion loss, electric noise during current-carrying sliding, temperature rise and the like) of the prepared ideal alloy test group;
compared with the performances of the existing mature silver-based sliding electric contact materials (AgCu10Ni2, AgCu20Ni2, AgCu10V0.2 and AgCu10V0.4), the comprehensive service performance of the newly developed Ag-6.13Cu-3.12Ni-0.18V electric contact is improved by more than 10 percent compared with the performances. Finally, screening out the novel silver-based electric contact material meeting the design requirement.
Example 2: Ag-Cu-Ni-V-Y sliding electric contact material
S1-1, silver, oxygen-free copper, nickel, vanadium and yttrium with the purity of 99.99% are used as raw materials, an upper die alloy is Ag-Cu-Ni-V-Y solute alloy (the components and the mass percentage are Ag, 87.8%, Cu, 7%, Ni, 5%, V, 0.1%, Y and 0.1%), and a lower die is Ag-Cu-Ni matrix alloy with the same concentration (the components and the mass percentage are Ag, 88.8%, Cu, 7%, Ni and 5%);
s1-2, obtaining a gradient sample with continuously changed components by adopting a high-flux gradient component directional solidification preparation method. FIG. 1 is a schematic view of directional solidification of a gradient composition material. The upper die contains solute alloy, and the lower die contains base alloy with equal concentration. The high-frequency induction heating is adopted, the flow of the solute alloy melt is controlled by using the stopper rod, the concentration of the solute in the metal liquid in the lower die is controlled, and finally the alloy ingot with phi 8mm multiplied by 200mm component gradient change is obtained. The adopted solidification process parameters are as follows: the temperature of the upper die is 1450 ℃, the temperature of the lower die is 1150 ℃, after the alloy is completely melted, the temperature is kept for 5min, the drawing is carried out at the blank drawing speed of 0.5mm/s, and the cooling water flow is 300L/h;
s1-3, the cast sample is continuously heat treated and processed. The vacuum homogenization heat treatment conditions are as follows: 630 ℃ for 5h, 5X 10-3Pa; after the homogenization heat treatment, cold drawing processing is carried out, and single pass is carried outThe secondary deformation amount is controlled to be 5 percent, the total deformation amount is 55 percent, and annealing is not carried out in the middle;
s1-4, testing the performances and components of the gradient alloy samples in the casting state, the heat treatment state and the processing state, such as hardness, resistivity and the like, at different positions, and screening out the optimal alloy component proportion of Ag-7.21Cu-5.17Ni-0.22V-0.19Y according to the performance requirements (when the sliding electric contact multi-component alloy material is designed, in order to simplify the test and highlight the performance comparison in the casting state, the processing state and the heat treatment state, the electric conductivity and the mechanical property of the material are mainly considered, and the material with lower contact resistance and higher strength (hardness) is expected to be obtained).
S2-1 adopts a fractional melting solidification high-flux preparation method to prepare the gradient structure alloy for the Ag-7.21Cu-5.17Ni-0.22V-0.19Y alloy with the optimal component ratio, and the schematic diagram of the principle is shown in figure 2. Firstly, an alloy sample with the optimal component ratio is smelted by induction heating, and the solidification process parameters are as follows: the drawing speed (0.5-2 mm/s), the heating temperature of 1350 ℃ and the cooling water flow rate of 300L/h. After the time of complete melting and heat preservation is 5min, firstly drawing a solidified ingot with phi 8mm multiplied by 30mm at the speed of 0.5mm/s through a drawing rod, then suspending a drawing device, changing the drawing speed, after heat preservation is carried out for 20s, starting the drawing device again to draw another section of ingot with different drawing speeds, suspending drawing again, and changing the drawing speed again; by analogy, a solidified cast ingot with the same components and different solidified structures is finally formed;
s2-2, representing the alloy structure and performance prepared at different traction speeds (0.5-2 mm/S), and screening out the optimal traction speed
S2-3, sequentially changing solidification process parameters such as heating temperature (1100-1400 ℃) and cooling water flow (200-500L/h), and repeating the operations of S2-1 and S2-2 to obtain alloy casting blanks under different solidification parameters. Finally, the optimum solidification process parameters are selected to be traction speed of 1.5mm/s, heating temperature of 1250 ℃, and cooling water flow of 400L/h.
S3-1, preparing the alloy ingot blank with the structure and the performance in gradient distribution by adopting a gradient temperature high-flux homogenization heat treatment method for the Ag-7.21Cu-5.17Ni-0.22V-0.19Y alloy ingot blank prepared by the optimal solidification process parameters. A schematic diagram of a gradient temperature high flux homogenization heat treatment apparatus is shown in FIG. 3. The heating mode is that a single-strand induction coil is adopted for heating, an experimental sample with the size of phi 8mm multiplied by 120mm traverses the induction coil and is placed in the middle of the induction coil, two ends of the experimental sample are supported by alumina ceramic plates with good heat insulation, the induction heating power is slowly increased, the temperature of the sample at the position of the induction coil reaches the set temperature of 760 ℃, then the heating power is kept unchanged, and the heating time is 2 hours. Measuring the temperature by an infrared thermometer, measuring the temperature every 5min after the temperature is stable, wherein the position interval of measuring points is 1cm, moving the fixed distance to the two ends each time by taking the position of the induction coil as the center, obtaining and recording a temperature value, and taking the average value of the measured values as the final temperature of a value taking point;
s3-2, representing the alloy structure and performance at different positions, and screening out the optimal homogenization heat treatment conditions according to the structure and performance requirements as follows: 615-2 h. (for simplicity of the experiment, time is considered herein as a fixed quantity, temperature is used as a variable, and after the optimum temperature is actually determined, the time conditions are changed in a vacuum tube furnace to determine the optimum time, and finally the temperature and time for the optimum homogenization heat treatment can be determined).
S4-1 is processed by the optimal homogenization heat treatment condition, the preparation of the alloy with different deformation amounts is realized by adopting a high-flux plastic deformation method, and the working principle diagram is shown in figure 4. Firstly, machining an alloy with the diameter of 8mm multiplied by 120mm to prepare a conical gradient sample with a thick end and a thin end;
s4-2, drawing the tapered gradient-shaped alloy sample to phi 3mm to obtain a high-flux experimental sample with deformation continuously changing from 20-85%. The alloy structures and the performances of different deformation quantities are characterized, and the optimal alloy deformation quantity is screened according to the structure and the performance requirements as follows: 70 percent.
S5-1, performing cold drawing on an alloy ingot blank with phi 8mm to a wire finished product with phi 3mm according to the optimal solidification process parameters (traction speed of 1.5mm/S, heating temperature of 1250 ℃, cooling water flow rate of 400L/h), the optimal homogenization heat treatment conditions (615-2 h) and the optimal plastic deformation conditions (the optimal alloy deformation is 70%) on the Ag-7.21Cu-5.17Ni-0.22V-0.19Y alloy with the optimal alloy components;
s5-2, on the existing electric contact performance characterization equipment, evaluating the sliding electric contact service performance (contact resistance, abrasion loss, electric noise during current-carrying sliding, temperature rise and the like) of the prepared ideal alloy test group;
compared with the performances of the existing mature silver-based sliding electric contact materials (AgCu10Ni2, AgCu20Ni2, AgCu10V0.2 and AgCu10V0.4), the comprehensive service performance of the newly developed electric contact of Ag-7.21Cu-5.17Ni-0.22V-0.19Y is improved by more than 10 percent compared with the performances. Finally, screening out the novel silver-based electric contact material meeting the design requirement.
Experiments show that when a novel sliding electric contact multi-element alloy material is developed, the method for rapidly researching and developing the novel sliding electric contact material can obviously reduce the research and development period and research and development cost, accelerate the development of the novel sliding electric contact material and accelerate the industrial application of the novel sliding electric contact material in devices such as micro motors, precise electronic instruments and the like.
The above embodiments are only some examples of the method for rapidly developing a novel experimental material for electrical contact according to the present invention, and several changes may be made in the above embodiments without departing from the scope of the present invention.
Claims (12)
1. A method for rapidly developing a novel electric contact material is characterized by comprising the following steps:
s1, obtaining high-quality component performance data through a gradient solidification high-throughput experiment to obtain a gradient alloy sample ingot;
s2, performing alloy ingot blank solidification preparation by adopting a fractional melting solidification high-flux preparation method;
s3, performing alloy heat treatment by adopting a gradient temperature high-flux homogenization heat treatment method;
s4, performing alloy plastic deformation processing by adopting a high-flux plastic deformation method;
and S5, evaluating and verifying the comprehensive performance of the electric contact material.
2. The method for rapidly developing a novel electrical contact material as claimed in claim 1, wherein the specific step of S1 comprises:
s1-1, obtaining an as-cast gradient alloy sample with continuously changed alloy components by adopting a high-flux gradient component directional solidification preparation method;
s1-2, continuously carrying out heat treatment and processing on the as-cast state gradient alloy sample to respectively obtain a heat treatment state gradient alloy sample and a processed state gradient alloy sample;
and S1-3, detecting the components and the performance of the cast-state gradient alloy sample, the heat-treated-state gradient alloy sample and the processed-state gradient alloy sample, and screening out the optimal alloy component proportion according to the performance requirement.
3. The method for rapidly developing a novel electric contact material as claimed in claim 2, wherein the directional solidification preparation method of the high-flux gradient component in S1-1 further comprises:
(1) the alloy crucible carrier used in the high-flux gradient component directional solidification preparation method comprises an upper die and a lower die, wherein the upper die is filled with solute alloy, and the lower die is filled with matrix alloy with equal concentration;
(2) the concentration of solute in the metal liquid in the lower die is controlled and realized by controlling the flow of the solute alloy melt through the stopper rod, and finally the gradient alloy sample ingot with the component gradient change characteristic is obtained.
4. The method for rapidly developing a novel electrical contact material as claimed in claim 2, wherein the heat treatment and processing in S1-2 further comprises:
(1) the time of the homogenization heat treatment is at least more than 4 hours, so that the uniformity of components, structures and performance is ensured;
(2) and (3) carrying out cold drawing processing after homogenizing heat treatment, wherein the single-pass deformation is controlled within 4-15%, the total deformation is controlled to be more than 50%, and annealing is not carried out in the middle.
5. The method for rapidly developing a novel electrical contact material as claimed in claim 1, wherein the specific step of S2 comprises:
s2-1, preparing a gradient structure alloy by adopting a fractional melting solidification high-flux preparation method, firstly, carrying out induction heating smelting on an alloy sample with the optimal component ratio, drawing out a section of solidified ingot through a drawing rod after the alloy sample is completely melted, then suspending a drawing device, changing the drawing speed, keeping the temperature for a period of time, then starting the drawing device again to draw out another section of ingot with different drawing speeds, suspending the drawing again, and changing the drawing speed again; by analogy, a solidified cast ingot with the same components and different solidified structures is finally formed; the optimal component proportion is selected according to the conductivity and mechanical property of the material and the standards of low contact resistance and high strength;
s2-2, representing the alloy structure and performance prepared at different traction speeds, and screening out the optimal traction speed;
s2-3, sequentially changing solidification process parameters such as heating temperature, cooling water flow and the like, repeating the operations of the step S2-1 and the step S2-2, obtaining alloy casting blanks under different solidification parameters, and screening out the optimal solidification process parameters.
6. The method for rapidly developing a novel electrical contact material as claimed in claim 1, wherein the specific step of S3 comprises:
s3-1, preparing an alloy ingot blank with a structure and performance in gradient distribution by adopting a gradient temperature high-flux homogenization heat treatment method;
s3-2, representing the alloy structure and mechanical property at different positions, and screening out the optimal homogenization heat treatment condition according to the structure and performance requirements.
7. The method for rapidly developing a novel electrical contact material as claimed in claim 6, wherein the high-flux homogenization heat treatment method in S3-1 further comprises:
(1) the heating mode is that a single-strand induction coil is adopted for heating, an experimental sample with a proper length traverses the induction coil and is placed in the middle, two ends of the experimental sample are supported by an alumina ceramic plate with good heat insulation, the induction heating power is slowly increased, the temperature of the sample at the position of the induction coil reaches the set temperature, then the heating power is kept unchanged, the middle position of the sample is locally heated, and the temperature is gradually reduced from the middle position to the two ends through heat transfer, so that the continuous change of the internal temperature of the sample is realized;
(2) measuring the temperature by an infrared thermometer, moving a fixed distance to two ends each time by taking the position of the induction coil as a center, and obtaining and recording a temperature value;
(3) by the heat treatment of (1) and (2), samples in which the temperature gradient was continuously changed were obtained, and two identical samples were obtained at a time.
8. The method for rapidly developing a novel electrical contact material as claimed in claim 1, wherein the specific step of S4 comprises:
s4-1, preparing alloys with different deformation amounts by adopting a high-flux plastic deformation method, firstly, machining the alloys after homogenization heat treatment to prepare alloy samples with gradient shapes;
s4-2, realizing high-flux preparation of alloys with different deformation amounts for the gradient shape by rolling or drawing processing means, representing the alloy structure and performance of different deformation amounts, screening out the optimal alloy deformation amount according to the requirements of the structure and performance, and optimizing the alloy plastic deformation process.
9. The method for rapidly developing a novel electrical contact material as claimed in claim 8, wherein the high-flux plastic deformation method in S4-1 further comprises:
(1) the gradient sample comprises a stepped, wedge or conical gradient sample;
(2) and rolling or drawing the gradient-shaped alloy sample to obtain a high-flux experimental sample with the deformation continuously changing from 20-85%.
10. The method for rapidly developing a novel electrical contact material as claimed in any one of claims 1 to 9, wherein the specific step of S5 comprises:
s5-1, performing sliding electrical contact service performance evaluation on the prepared high-throughput experiment sample on the existing electrical contact performance characterization equipment;
and S5-2, comparing the performances of the sliding electric contact material with those of the existing sliding electric contact material, and finally screening out the novel electric contact material meeting the design requirements.
11. The method for rapidly developing a novel electrical contact material as claimed in claim 10, wherein the electrical contact material is a silver-based electrical contact material.
12. The method for rapidly developing a novel electrical contact material as claimed in claim 11, wherein the electrical contact material is Ag-6.13Cu-3.12Ni-0.18V or Ag-7.21Cu-5.17 Ni-0.22V-0.19Y.
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Application publication date: 20210810 |