CN114871382A - Preparation method of micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material - Google Patents
Preparation method of micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material Download PDFInfo
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- CN114871382A CN114871382A CN202210461469.XA CN202210461469A CN114871382A CN 114871382 A CN114871382 A CN 114871382A CN 202210461469 A CN202210461469 A CN 202210461469A CN 114871382 A CN114871382 A CN 114871382A
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- 239000000843 powder Substances 0.000 title claims abstract description 86
- 239000002131 composite material Substances 0.000 title claims abstract description 71
- 238000002360 preparation method Methods 0.000 title claims abstract description 20
- 239000000919 ceramic Substances 0.000 claims abstract description 155
- 239000006260 foam Substances 0.000 claims abstract description 73
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 63
- 239000002245 particle Substances 0.000 claims abstract description 53
- 239000011651 chromium Substances 0.000 claims abstract description 51
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 48
- 239000000853 adhesive Substances 0.000 claims abstract description 37
- 230000001070 adhesive effect Effects 0.000 claims abstract description 37
- 238000001035 drying Methods 0.000 claims abstract description 37
- 229910001018 Cast iron Inorganic materials 0.000 claims abstract description 32
- 238000002156 mixing Methods 0.000 claims abstract description 29
- 238000000576 coating method Methods 0.000 claims abstract description 27
- 239000011248 coating agent Substances 0.000 claims abstract description 25
- 239000000203 mixture Substances 0.000 claims abstract description 23
- 238000005266 casting Methods 0.000 claims abstract description 15
- 239000007788 liquid Substances 0.000 claims abstract description 14
- 244000035744 Hura crepitans Species 0.000 claims abstract description 13
- 238000005520 cutting process Methods 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims abstract description 10
- 238000001816 cooling Methods 0.000 claims abstract description 8
- 239000011230 binding agent Substances 0.000 claims abstract description 5
- 239000010410 layer Substances 0.000 claims description 17
- 238000003756 stirring Methods 0.000 claims description 13
- 229910052759 nickel Inorganic materials 0.000 claims description 10
- 239000000126 substance Substances 0.000 claims description 9
- 229910052748 manganese Inorganic materials 0.000 claims description 7
- 229910052750 molybdenum Inorganic materials 0.000 claims description 7
- 239000002344 surface layer Substances 0.000 claims description 7
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 3
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims description 2
- 239000004115 Sodium Silicate Substances 0.000 claims description 2
- 239000000835 fiber Substances 0.000 claims description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 9
- 238000005086 pumping Methods 0.000 abstract 1
- 229920006248 expandable polystyrene Polymers 0.000 description 24
- 239000011159 matrix material Substances 0.000 description 23
- 229910052751 metal Inorganic materials 0.000 description 22
- 239000002184 metal Substances 0.000 description 22
- 238000012360 testing method Methods 0.000 description 20
- 238000004519 manufacturing process Methods 0.000 description 9
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- 150000001247 metal acetylides Chemical class 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
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- 238000009736 wetting Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
- B22C7/023—Patterns made from expanded plastic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/06—Cast-iron alloys containing chromium
- C22C37/08—Cast-iron alloys containing chromium with nickel
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
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- Manufacture Of Alloys Or Alloy Compounds (AREA)
Abstract
The invention discloses a preparation method of a micro powder coated hexagonal prism shape ZTA/Fe composite material, belonging to the technical field of mechanical part casting, comprising the following process steps: cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model; uniformly mixing the ceramic micro powder and the adhesive; adding ZTA ceramic particles into the above mixed material, and mixing; putting a mixture of ceramic micro powder, a binder and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model; bonding a layer of EPS pattern on the hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model; and (3) coating a refractory coating on the surface of the model, putting the model into a sand box, pumping negative pressure, pouring the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the hexagonal prism-shaped honeycomb ZTA/Fe composite material coated by the ceramic micro powder.
Description
Technical Field
The invention relates to the technical field of mechanical part casting, in particular to a preparation method of a micro powder coated hexagonal prism shape ZTA/Fe composite material.
Background
The breakage, corrosion and abrasion are three main failure modes of materials and equipment, and the inevitable abrasion phenomenon of the materials and the equipment in the service process causes serious material consumption and energy consumption. The wear-resistant metal material has great demand in many important industrial fields such as coal mine, metallurgy, electric power, building, national defense, traffic and the like, and a large part of materials of the wear-resistant metal parts in the industries are high-chromium cast iron. The working condition of the wear-resistant metal part is characterized by mainly bearing complex stress and strong friction and impact, the service condition is very severe, the severe use working condition causes great material loss, according to analysis and calculation of related national departments, the energy loss caused by friction and wear accounts for about 30-50% of the total energy loss, the metal material consumed by friction and wear in China is up to 500 ten thousand tons every year, the economic loss exceeds 800 yuan, accounts for about 2% of the total production value of China, and is increased at a speed of 15% every year, so that the wear-resistant material with higher performance is developed, the service life of the wear-resistant part is prolonged, the loss of energy and mineral materials is reduced, and the long-term development of the national economy is greatly contributed.
Aiming at different working conditions, schlenter E and the like have carried out a great deal of research on the particle reinforced steel-based wear-resistant composite materials by schlenter E and other schlenter enterprises 2 O 3 The result of the particle reinforced 316L stainless steel-based composite material shows that Al 2 O 3 The presence of the particles does not affect the corrosion resistance of the composite, which is mainly related to the steel matrix.
Some students uniformly mix ZTA ceramic particles with a self-made binder to prepare a ZTA ceramic preform, and the ZTA ceramic preform is compounded with molten metal by a pressureless cast-infiltration method to obtain the ZTA ceramic particle reinforced steel-based composite material with the volume fraction of 47-55%, wherein the wear resistance of the composite material is greatly improved compared with that of a metal matrix.
In the prior art, ZTA ceramic is prepared for modification treatment, the ZTA ceramic particles after modification treatment are added into a mould with a cavity in a wafer shape, demoulding is carried out after compression forming, and heating and drying are carried out in a tube furnace with argon protection to prepare a ceramic preform.
Also, it is prepared by mixing various metal powders, such as Fe-Cr-Ni-Ti micropowder coated ZTAThe ceramic prefabricated body is produced through mixing pure Fe, Cr, Ni and Ti powder with ZTA ceramic, setting and compacting the prefabricated body in a mold, and introducing CO continuously 2 Solidifying the gas, drying and demoulding to obtain the target product Fe-Cr-Ni-Ti micro powder coated honeycomb ZTA ceramic preform.
In the prior art, Fe-Ti adhesives with different Ti contents are used for preparing porous ZTA ceramic particle preforms, then the prepared preforms are placed into a lost foam, composite materials are obtained through a lost foam casting technology, in the three-body abrasive wear detection of a sample, the wear resistance of the composite materials containing 10 wt% of Ti adhesives is 3 times that of high-chromium cast iron, and the wear resistance of the composite materials containing 15 wt% of Ti adhesives is 2.4 times that of the high-chromium cast iron.
In summary, ZTA ceramic has good toughness, ZTA ceramic particle reinforced steel-iron matrix composite material has good application prospect, but ZTA ceramic particle and steel metal liquid have poor wettability, the bonding strength is low, the composite material is easy to have particle shedding phenomenon in the abrasion process, and the production cost is high, thus being not suitable for mass production.
Disclosure of Invention
Aiming at the problems of complex process, low bonding strength of ZTA particles and a metal matrix and high production cost and complex process of the existing ZTA ceramic steel material preform preparation technology, the invention aims to provide a preparation method of a micro powder coated hexagonal prism shaped ZTA/Fe composite material.
In order to achieve the purpose, the invention adopts the following technical scheme:
a preparation method of a micro powder coated hexagonal prism shape ZTA/Fe composite material comprises the following process steps:
a. cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. uniformly mixing the ceramic micro powder and the adhesive;
c. adding ZTA ceramic particles into the mixture of the ceramic micropowder and the adhesive, and uniformly mixing;
d. putting a mixture of ceramic micro powder, a binder and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying to obtain a hexagonal prism-shaped honeycomb ZTA ceramic prefabricated body lost foam model;
e. bonding a layer of EPS pattern on the hexagonal prism-shaped honeycomb lost foam model of the ZTA ceramic preform;
f. and (3) smearing refractory coating on the surface of the hexagonal prism-shaped honeycomb lost foam model with the EPS pattern adhered on the surface layer and the ZTA ceramic preform contained in the hexagonal prism-shaped honeycomb lost foam model, putting the hexagonal prism-shaped honeycomb lost foam model into a sand box, vacuumizing, pouring the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the ceramic micro powder coated hexagonal prism-shaped honeycomb ZTA/Fe composite material.
The technical scheme of the invention is further improved as follows: the density of the EPS foam board in the step a is 22-25g/dm 3 The shape and the size of the hexagonal prism-shaped honeycomb lost foam model can be adjusted according to the requirements of parts, for example, the side length of the hexagonal prism is 10.4 mm.
The technical scheme of the invention is further improved as follows: in the step b, the adding amount of the ceramic micro powder accounts for 4-12% of the mass of the ZTA ceramic, the adding amount of the adhesive accounts for 8-15% of the mass of the ZTA, and the adhesive is a sodium silicate inorganic adhesive.
The technical scheme of the invention is further improved as follows: the ceramic micro powder in the step b is Al 2 O 3p 、Al 2 O 3f 、TiC、Cr 3 C 2 、TiO 2 、TiNC、B 4 C、WC、SiC、Ni、Al、Co、Cr、NiCrBSi、MnO 2 One or more of them, the grain size of the ceramic micro powder is 6.5-23 μm, Al 2 O 3f The fiber size is 10-20um in diameter and 0.3-0.7mm in length.
The technical scheme of the invention is further improved as follows: in the step b, the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 200 and 350 seconds in the temperature of 120 and 200r/min, wherein in the step c, the mixing conditions of the ceramic micro powder, the adhesive ZTA and the ceramic particles are as follows: stirring for 200 and 350 seconds in the temperature of 120 and 200r/min, and fully ensuring that the surfaces of the ZTA ceramic particles are uniformly coated with the ceramic micro powder.
The technical scheme of the invention is further improved as follows: and d, drying the hexagonal prism-shaped honeycomb lost foam model in the step d at the drying temperature of 50-60 ℃ for 20-24 h.
The technical scheme of the invention is further improved as follows: the coating process of the refractory coating in the step f is as follows: after the refractory coating is coated, drying is carried out at the drying temperature of 50-60 ℃, and the drying is repeated for three times, wherein the drying time is 7-8h each time.
The technical scheme of the invention is further improved as follows: the chemical components and the mass percent content of the cast high-chromium cast iron are as follows: 2.8-3.2%, Si: 0.6-1.0%, Mn: 0.8-1.2%, Cr: 25-27%, Mo: 0.5-1.0%, Ni: 0.3 to 0.6 percent.
The technical scheme of the invention is further improved as follows: the casting process is carried out under the negative pressure of 0.03-0.06 MPa, and the casting temperature is 1470-1520 ℃.
Due to the adoption of the technical scheme, the invention has the following technical effects:
the EPS foam board is used for cutting and bonding the hexagonal prism-shaped honeycomb lost foam model, the hexagonal prism-shaped honeycomb lost foam model is low in preparation cost, is not limited to the hexagonal prism shape, can adapt to the shape preparation of any complex shape, and a mixture of ceramic micro powder, a bonding agent and ZTA ceramic does not need to be taken out in the production process of the ZTA/Fe composite material, so that the production process is simple and convenient, and the production efficiency is improved.
In the preparation process of preparing the ZTA/Fe composite material, a hexagonal prism-shaped porous honeycomb hole pattern is used, the contact area of the molten metal and the ZTA ceramic preform is increased, the impregnation of the molten metal on the ZTA ceramic preform is facilitated, and the bonding strength of the ZTA ceramic and the metal matrix and the wear resistance of the ZTA/Fe composite material casting are greatly improved due to the addition of the ceramic micro powder.
According to the method, high-chromium cast iron is used as a metal matrix, ZTA ceramic particles are used as a reinforcement, proper ceramic micro powder is selected to treat the surfaces of the ZTA ceramic particles, the surfaces of the ZTA ceramic particles are made into a ceramic prefabricated body with a hexagonal prism honeycomb configuration, the ZTA ceramic particle reinforced high-chromium cast iron based honeycomb configuration composite material is prepared, and a reaction type interface is obtained. In order to solve the problems of low interface bonding strength and the like existing between ZTA ceramic particles and high-chromium cast iron melt and obtain a reaction type interface, the patent discloses a regular hexagonal honeycomb ZTA ceramic with side lengths of 8.7mm and 10.4mmAdding Al into the particle preform 2 O 3p 、Al 2 O 3f 、TiC、Cr 3 C 2 、TiNC、B 4 C、WC、SiC、Ni、Al、Co、Cr、MnO 2 Active ceramic micro powder such as NiCrBSi and the like are used for preparing ZTA ceramic particle reinforced high-chromium cast iron test blocks with different active ceramic micro powder contents, and the influence of different ceramic particle types and adding amounts on the interface layer structure and the phase of the ZTA ceramic particle reinforced high-chromium cast iron composite material is researched by utilizing microscopic detection means such as SEM, EDS, XRD and the like, so that the micro powder coated hexagonal prism-shaped ZTA/Fe composite material lost foam casting method which is high in performance, suitable for mass production and suitable for mass production is obtained.
Drawings
FIG. 1 is a schematic view of a lost foam model used to make hexagonal prismatic cellular ZTA preforms;
FIG. 2 is a cross-sectional view of FIG. 1;
FIG. 3 is a macrostructure diagram of a test piece in example 1 without adding the ceramic fine powder;
FIG. 4 is a microstructure diagram of a test piece without ceramic fine powder in example 1;
FIG. 5 is a macroscopic structure view of a test block to which ceramic fine powder was added in example 2;
FIG. 6 is an EDS spot scan of the composite test block with ceramic fine powder added in example 2;
FIG. 7 is a XRD test result chart of the composite material test block added with ceramic micropowder in example 2;
FIG. 8 is a graph showing the wear profile of the composite test block with the ceramic fine powder added in example 2.
Detailed Description
The technical solution of the present invention will be described in detail with reference to the following embodiments.
Example 1
a. Cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. uniformly mixing the adhesive and ZTA ceramic particles, wherein the addition amount of the adhesive accounts for 10% of the mass of the ZTA; the mixing conditions of the adhesive and ZTA ceramic particles are as follows: stirring for 300s at 150 r/min;
c. putting the mixture of the adhesive and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying at 50 ℃ for 22 hours;
d. bonding a layer of EPS pattern on the hexagonal prism-shaped lost foam model containing the adhesive and ZTA ceramic mixture;
e. coating a refractory coating on the surface of the hexagonal prism-shaped lost foam model with the surface layer adhered with the EPS pattern and the interior containing the adhesive and ZTA ceramic mixture, drying at the drying temperature of 55 ℃ after coating the refractory coating, and repeating for three times, wherein the drying time is 7 hours each time, so as to obtain the hexagonal prism-shaped honeycomb-shaped lost foam model;
f. putting the hexagonal prism-shaped honeycomb lost foam model containing the adhesive and ZTA ceramic mixture into a sand box, and combining the sand box with a pouring system to form a box;
g. and pouring the high-chromium cast iron metal liquid under negative pressure, pouring the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the hexagonal prism-shaped honeycomb ZTA/Fe composite material.
The chemical components and the mass percent content of the cast high-chromium cast iron are as follows: 2.8-3.2%, Si: 0.6-1.0%, Mn: 0.8-1.2%, Cr: 25-27%, Mo: 0.5-1.0%, Ni: 0.3 to 0.6 percent. The negative pressure is 0.04MPa, and the pouring temperature is 1480 ℃.
Samples were cut from the above composite material, the properties were measured and the metallographic structure was observed. The experimental data, macro and micro-tissues obtained were as follows:
TABLE 1 abrasion test parameters
TABLE 2 abrasion resistance data of test blocks of ceramic-free micropowder composite material
The macroscopic structure of example 1 is shown in fig. 3;
the microstructure of example 1 is shown in FIG. 4.
Example 2
a. Cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model as shown in figure 1;
b. the types of the ceramic micro powder and the relative ZTA ceramic particles are as follows by mass: b is 4 C：2％，Al 2 O 3p ：2％，Al 2 O 3f ：1.5％，TiO 2 ：1％，Ni：1％，Al：0.5％，Cr：0.5％，NiCrBSi：0.5％；
c. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s at 180 r/min;
d. adding ZTA ceramic particles into the mixture of the ceramic micro powder and the adhesive, and uniformly mixing, wherein the mixing conditions are as follows: stirring for 260s at 180 r/min;
e. putting a mixture of ceramic micro powder, a bonding agent and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying at 55 ℃ for 24 hours to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model;
f. bonding a layer of EPS pattern on a hexagonal prism-shaped honeycomb lost foam model containing a ceramic micro powder, a bonding agent and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic prefabricated body);
g. coating a refractory coating on the surface of a hexagonal prism-shaped honeycomb lost foam model with an EPS (expandable polystyrene) pattern adhered on the surface layer and a ZTA ceramic prefabricated body contained in the hexagonal prism-shaped honeycomb lost foam model, drying at the drying temperature of 55 ℃ after the refractory coating is coated, and repeating for three times, wherein the drying time is 8 hours each time;
h. putting the hexagonal prism-shaped honeycomb lost foam model containing the ZTA ceramic preform inside into a sand box, and combining the sand box with a pouring system to form a box;
i. and pouring high-chromium cast iron metal liquid under negative pressure, filling the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the micro powder coated hexagonal prism-shaped honeycomb ZTA/Fe composite material.
The chemical components and the mass percent content of the cast high-chromium cast iron are as follows: 2.8-3.2%, Si: 0.6-1.0%, Mn: 0.8-1.2%, Cr: 25-27%, Mo: 0.5-1.0%, Ni: 0.3 to 0.6 percent. The casting is carried out under the negative pressure of 0.04MPa and the casting temperature is 1500 ℃.
Samples were cut from the composite material of example 2, the properties were measured and the metallographic structure was observed. The experimental data, macro and micro-tissues obtained were as follows:
table 3 test block abrasion resistance data for examples 1 and 2
Table 4 example 2 test block EDS spot scan results
The macroscopic structure of example 2 is shown in figure 5.
An EDS spot scan of the composite test block of example 2 is shown in figure 6.
The XRD test result of the composite material test block of example 2 is shown in FIG. 7, and FeB and Fe are found 2 B、Zr 3 NiO、Al 74 Cr20Si 6 、Fe 0.88 Ti 1.11 Zr 0.94 O 5 And (4) equivalent new phases.
Example 3
a. Cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. the types and relative ZTA ceramic particles of the ceramic micro powder are as follows: b is 4 C：2.0％，Al 2 O 3f ：2.0％、Cr 3 C 2 ：2.0％、TiNC：1.0％、MnO 2 ：1.0％、SiC：0.5％、NiCrBSi：0.5％；
c. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s at 180 r/min;
d. adding ZTA ceramic particles into the mixture of the ceramic micro powder and the adhesive, and uniformly mixing, wherein the mixing conditions are as follows: stirring for 260s at 180 r/min;
e. putting a mixture of ceramic micro powder, adhesive and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying for 24 hours at 55 ℃ to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model;
f. bonding a layer of EPS pattern on a hexagonal prism-shaped honeycomb lost foam model containing a ceramic micro powder, a bonding agent and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic prefabricated body);
g. adhering an EPS (expandable polystyrene) pattern on the surface layer, smearing a refractory coating on the surface of a hexagonal prism-shaped honeycomb lost foam model containing a ZTA ceramic prefabricated body in the interior, drying at the drying temperature of 55 ℃ after smearing the refractory coating, and repeating for three times, wherein the drying time is 8h each time;
h. putting the hexagonal prism-shaped honeycomb lost foam model containing the ZTA ceramic preform inside into a sand box, and combining the sand box with a pouring system to form a box;
i. and pouring high-chromium cast iron metal liquid under negative pressure, filling the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the micro powder coated hexagonal prism-shaped honeycomb ZTA/Fe composite material.
The chemical components and the mass percent content of the cast high-chromium cast iron are as follows: 2.8-3.2%, Si: 0.6-1.0%, Mn: 0.8-1.2%, Cr: 25-27%, Mo: 0.5-1.0%, Ni: 0.3 to 0.6 percent. The casting is carried out under the negative pressure of 0.04MPa and the casting temperature is 1500 ℃.
Samples were cut from the above composite and properties were measured. The experimental data obtained were as follows:
TABLE 5 ceramic micropowder coating ZTA/Fe composite material test block wear-resistant data
Example 4
a. And cutting and bonding the EPS foam plate to obtain the hexagonal prism-shaped lost foam model.
b. The types and relative ZTA ceramic particles of the ceramic micro powder are as follows: al (Al) 2 O 3p ：2.0％、Al 2 O 3f ：2.0％、Cr 3 C 2 ：2.0％、TiNC：1.0％、Co：1.0％、Cr：1.0％、MnO 2 ：0.5％、WC：0.5％；
c. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s at 180 r/min;
d. adding ZTA ceramic particles into the mixture of ceramic micropowder and binder, and mixing uniformly under the following conditions: stirring for 260s at 180 r/min;
e. putting a mixture of ceramic micro powder, a bonding agent and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying at 55 ℃ for 24 hours to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model;
f. bonding a layer of EPS pattern on a hexagonal prism-shaped honeycomb lost foam model containing a ceramic micro powder, a bonding agent and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic prefabricated body);
g. coating a refractory coating on the surface of a hexagonal prism-shaped honeycomb lost foam model with an EPS (expandable polystyrene) pattern adhered on the surface layer and a ZTA ceramic prefabricated body contained in the hexagonal prism-shaped honeycomb lost foam model, drying at the drying temperature of 55 ℃ after the refractory coating is coated, and repeating for three times, wherein the drying time is 8 hours each time;
h. putting the hexagonal prism-shaped honeycomb lost foam model containing the ZTA ceramic preform inside into a sand box, and combining the sand box with a pouring system to form a box;
i. and pouring high-chromium cast iron metal liquid under negative pressure, filling the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the micro powder coated hexagonal prism-shaped honeycomb ZTA/Fe composite material.
The chemical components and the mass percent content of the cast high-chromium cast iron are as follows: 2.8-3.2%, Si: 0.6-1.0%, Mn: 0.8-1.2%, Cr: 25-27%, Mo: 0.5-1.0%, Ni: 0.3 to 0.6 percent. The casting is carried out under the negative pressure of 0.04MPa and the casting temperature is 1500 ℃.
TABLE 6 ceramic micropowder coating ZTA/Fe composite material test block wear-resistant data
Example 5
a. Cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. the types and relative ZTA ceramic particles of the ceramic micro powder are as follows: al (Al) 2 O 3p ：2.0％、Al 2 O 3f ：2.0％、TiNC：1.5％、Cr 3 C 2 ：1.0％、MnO 2 ：1.0％、Co：0.5％、NiCrBSi：0.5％、Ni：0.5％、B 4 C：0.5％；
c. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s at 180 r/min;
d. adding ZTA ceramic particles into the mixture of the ceramic micro powder and the adhesive, and uniformly mixing, wherein the mixing conditions are as follows: stirring for 260s at 180 r/min;
e. putting a mixture of ceramic micro powder, a bonding agent and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying at 55 ℃ for 24 hours to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model; (ii) a
f. Bonding a layer of EPS pattern on a hexagonal prism-shaped honeycomb lost foam model containing a ceramic micro powder, a bonding agent and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic prefabricated body);
g. coating a refractory coating on the surface of a hexagonal prism-shaped honeycomb lost foam model with an EPS (expandable polystyrene) pattern adhered on the surface layer and a ZTA ceramic prefabricated body contained in the hexagonal prism-shaped honeycomb lost foam model, drying at the drying temperature of 55 ℃ after the refractory coating is coated, and repeating for three times, wherein the drying time is 8 hours each time;
h. putting the hexagonal prism-shaped honeycomb lost foam model containing the ZTA ceramic preform inside into a sand box, and combining the sand box with a pouring system to form a box;
i. and pouring high-chromium cast iron metal liquid under negative pressure, filling the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the micro powder coated hexagonal prism-shaped honeycomb ZTA/Fe composite material.
The chemical components and the mass percent content of the cast high-chromium cast iron are as follows: 2.8-3.2%, Si: 0.6-1.0%, Mn: 0.8-1.2%, Cr: 25-27%, Mo: 0.5-1.0%, Ni: 0.3 to 0.6 percent. The casting is carried out under the negative pressure of 0.04MPa and the casting temperature is 1500 ℃.
Samples were cut from the composite material and the properties were measured. The experimental data obtained were as follows:
TABLE 7 wear-resistant data of ceramic micropowder coated ZTA/Fe composite material test block
In the above examples 2 to 5, the wear resistance of the ZTA/Fe composite materials was greatly improved, which indicates that after the ZTA ceramic particles were coated with the active fine powder, the transition layer between the metal matrix and the ceramic particles had an element diffusion behavior, and the element in the active fine powder had a chemical reaction with both the metal matrix and the ceramic particles at a high temperature, and thus it was confirmed that the transition layer had different degrees of reactive wetting with the metal matrix and the ceramic particles, that is, there was metallurgical bonding between the transition layer and the metal matrix and the ceramic particles.
After grinding and polishing the high-chromium cast iron samples, randomly finding flat and smooth parts of each sample, punching 9 points in an equidistant distribution manner, and recording the Vickers hardness; the composite material sample is obtained by taking 3 points at three positions of a metal matrix, ceramic particles and a transition layer at equal intervals, taking 3 groups, respectively recording the hardness and then taking an average value.
TABLE 6 average microhardness of ZTA/Fe composite materials
The hardness of the transition layer of the composite material added with the active micro powder is obviously improved compared with that of the middle layer without the active micro powder.
The wear resistance of the ZTA/Fe composite material is obviously enhanced after the ZTA ceramic particles are added into the high-chromium cast iron metal matrix, the wear resistance of the examples 2, 3, 4 and 5 is higher than that of the samples of the examples 1 and the high-chromium cast iron matrix, the bonding property between the ceramic particles which are not coated with the active micro powder and the metal matrix is poor through analyzing the wear mechanism, and the hard and brittle carbides in the matrix which is relatively far away from the matrix which is closer to the ceramic particles are seriously peeled. The reason for this phenomenon is probably that the metal matrix surrounding the ceramic particles forms more hard and brittle carbides under the action of the 'micro-chilling blocks' of the ceramic particles, and after the metal matrix is gradually worn, the carbides fall off, so that the bearing effect of the metal matrix on the ceramic particles is reduced, cracks are generated between the metal matrix and the ceramic particles under the action of wear, and the ceramic particles tend to fall off from the matrix. After the micro powder is added, the wear appearance of the sample mainly comprises micro-cutting scratches and furrows, the phenomenon of peeling is not easy to occur due to the increase of the bonding strength of ZTA and the matrix, in addition, a wear-resistant phase appears on a transition layer between ZTA particles and the metal matrix, and the hardness of the transition layer is also increased, so the quality loss caused by wear of abrasive particles is effectively reduced, and the wear resistance of the composite material is improved.
Example 6
In this embodiment, the shape and size of the cellular ZTA/Fe composite material preform lost foam model are examined, the adopted ZTA ceramic particles, ceramic micro powder components and the percentage of the adopted ceramic micro powder, the chemical components of the poured high-chromium cast iron, the mass percentages of the chemical components, and the test steps are the same as those in embodiment 2, the difference is that the shape and size of the cellular ZTA/Fe composite material preform lost foam model are the same, the micro powder-coated hexagonal prism-shaped cellular ZTA/Fe composite material is prepared by using the different shapes and sizes of the preform lost foam models, and the wear resistance and hardness test is performed, specifically, the following table:
therefore, the honeycomb ZTA/Fe composite material preform lost foam model is a hexagonal prism, when the side length of the hexagonal prism is 10.4mm, the wear resistance is best, and the hardness value of the transition layer is highest.
Claims (10)
1. A preparation method of a micro powder coated hexagonal prism shape ZTA/Fe composite material comprises the following process steps:
a. cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. uniformly mixing the ceramic micro powder and the adhesive;
c. adding ZTA ceramic particles into the mixture of the ceramic micropowder and the adhesive, and uniformly mixing;
d. putting a mixture of ceramic micro powder, a binder and ZTA ceramic into a pre-prepared hexagonal prism-shaped lost foam model, and drying to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model;
e. bonding a layer of EPS pattern on the hexagonal prism-shaped honeycomb ZTA/Fe composite material prefabricated body lost foam model;
f. and (3) smearing refractory coating on the surface of the hexagonal prism-shaped honeycomb lost foam model with the EPS pattern adhered on the surface layer and the ZTA ceramic preform contained in the hexagonal prism-shaped honeycomb lost foam model, putting the hexagonal prism-shaped honeycomb lost foam model into a sand box, vacuumizing, pouring the poured high-chromium cast iron metal liquid along a pouring system, and cooling to obtain the ceramic micro powder coated hexagonal prism-shaped honeycomb ZTA/Fe composite material.
2. The preparation method of the micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material according to claim 1, which is characterized in that: the density of the EPS foam board in the step a is 22-25g/dm 3 。
3. The preparation method of the micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material according to claim 1, which is characterized in that: in the step b, the adding amount of the ceramic micro powder accounts for 4-12% of the mass of the ZTA ceramic, the adding amount of the adhesive accounts for 8-15% of the mass of the ZTA, and the adhesive is a sodium silicate inorganic adhesive.
4. The preparation method of the micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material according to claim 1, which is characterized in that: the ceramic micro powder in the step b is Al 2 O 3p 、Al 2 O 3f 、TiC、Cr 3 C 2 、TiO 2 、TiNC、B 4 C、WC、SiC、Ni、Al、Co、Cr、NiCrBSi、MnO 2 One or more of them are mixed.
5. The preparation method of the micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material according to claim 4, wherein the preparation method comprises the following steps: the grain size of the ceramic micro powder is 6.5-23 mu m, Al 2 O 3f The fiber size is 10-20um in diameter and 0.3-0.7mm in length.
6. The preparation method of the micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material according to claim 4, wherein the preparation method comprises the following steps: in the step b, the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 200 and 350 seconds in the temperature of 120 and 200r/min, wherein the mixing conditions of the ceramic micro powder, the adhesive and the ZTA ceramic particles in the step c are as follows: stirring for 200 and 350 seconds in 200 and 200 r/min.
7. The preparation method of the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 1, which is characterized by comprising the following steps: and d, drying the hexagonal prism-shaped honeycomb lost foam model in the step d at the drying temperature of 50-60 ℃ for 20-24 h.
8. The preparation method of the micro-powder-coated hexagonal prism-shaped ZTA/Fe composite material according to claim 1, which is characterized in that: the coating process of the refractory coating in the step f is as follows: after the refractory coating is coated, drying is carried out at the drying temperature of 50-60 ℃, and the drying is repeated for three times, wherein the drying time is 7-8h each time.
9. The application of the micro powder coated hexagonal prism shape ZTA/Fe composite material prepared according to claim 1, which is characterized in that: the chemical components and the mass percent content of the cast high-chromium cast iron are as follows: 2.8-3.2%, Si: 0.6-1.0%, Mn: 0.8-1.2%, Cr: 25-27%, Mo: 0.5-1.0%, Ni: 0.3 to 0.6 percent.
10. The application of the micro powder coated hexagonal prism shape ZTA/Fe composite material prepared according to claim 9, which is characterized in that: the casting process is carried out under the negative pressure of 0.03-0.06 MPa, and the casting temperature is 1470-1520 ℃.
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