CN114985708A - Method for preparing carbide ceramic reinforced steel-based surface composite material by thermal explosion reaction - Google Patents
Method for preparing carbide ceramic reinforced steel-based surface composite material by thermal explosion reaction Download PDFInfo
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Abstract
The invention discloses a method for preparing a carbide ceramic reinforced steel-based surface composite material by thermal explosion reaction, which comprises the following steps: uniformly mixing raw material powder of a prefabricated ceramic reinforced composite layer, and granulating to obtain pre-reaction pellets; filling the pre-reaction pellets into a metal grid, bonding the pre-reaction pellets and the metal grid to form a reaction template, and stacking and connecting one or more layers of reaction templates to form a pre-reaction layer; fixing a pre-reaction layer with the shape and the size matched with the casting at a position needing to be enhanced on the inner surface of a cavity of the casting; and (3) pouring the steel metal liquid into a casting cavity, so that the pre-reaction layer is subjected to high-temperature thermal explosion reaction, the metal grid is melted, and micron-level carbide ceramic particles are generated in situ to form a ceramic reinforced composite layer. The ceramic reinforced composite layer solves the problems of air holes, impurities and uneven distribution of a reinforcing phase in the existing ceramic reinforced composite layer.
Description
Technical Field
The invention belongs to the field of metal materials, and particularly relates to a method for preparing a carbide ceramic reinforced steel-based surface composite material through thermal explosion reaction.
Background
The casting and infiltration method is a material surface compounding technology which enables the surface of a metal casting to have special structure and performance, and the poured liquid metal permeates into an alloy layer or a ceramic layer which is fixed in a specific position of a casting mould cavity in advance through pores and forms a metallurgically bonded alloy/ceramic strengthening layer on the surface of the casting after solidification. The technical method is simple, economical and applicable, does not need special equipment, has good application prospect in the aspect of surface strengthening of products such as steel castings, iron castings, copper alloy castings and the like, and can effectively improve the wear resistance, corrosion resistance and high temperature resistance of the castings. However, in the casting infiltration process, the wetting ability of the high-temperature molten metal to most of the alloy layers or ceramic layers is poor, the infiltration ability of the molten metal is seriously influenced, the reinforced layer has air holes, inclusions, uneven distribution of reinforced phases and the like, and the reinforced part can only be in a flat plate shape, so that the popularization and the application of the casting infiltration technology are restricted.
Disclosure of Invention
The invention aims to provide a method for preparing a carbide ceramic reinforced steel-based surface composite material by thermal explosion reaction, which aims to solve the problems of air holes, inclusion and uneven distribution of reinforced phases of the existing ceramic reinforced composite layer.
The invention adopts the following technical scheme: the method for preparing the carbide ceramic reinforced steel-based surface composite material by the thermal explosion reaction comprises the following steps:
uniformly mixing raw material powder of a prefabricated ceramic reinforced composite layer, adding a PVA solution with the mass fraction of 4-7% as a binder, uniformly stirring, pressing and molding, crushing, sieving and granulating to obtain pre-reaction pellets;
uniformly filling the pre-reaction pellets into a metal grid, and bonding the pre-reaction pellets and the metal grid to form a reaction template by using a phenolic resin alcohol solution with the mass fraction of 5-10% as a bonding agent;
one or more layers of reaction templates are stacked and connected by taking phenolic resin alcohol solution with the mass fraction of 5-10% as a binder to form a pre-reaction layer;
fixing a pre-reaction layer with the shape and the size matched with the casting at a position needing to be enhanced on the inner surface of a cavity of the casting;
and (3) pouring the steel metal liquid with the temperature of 1350-1650 ℃ into a casting cavity, so that the pre-reaction layer is subjected to high-temperature thermal explosion reaction under a high-temperature condition, the metal grid is melted, micron-level carbide ceramic particles are generated in situ, and the carbide ceramic particles are diffused in the steel metal liquid to form a ceramic reinforced composite layer.
Furthermore, the raw material powder is graphite powder and metal powder, the mass ratio of the graphite powder to the metal powder is determined by the stoichiometric ratio of the carbide ceramic as a reaction product, and the particle size of each raw material powder is 5-100 micrometers.
Further, in the step (1), after the raw material powder is granulated, pre-reaction pellets with the particle size of 1-3 mm are formed, the porosity of the pre-reaction pellets is 20-50%, the mesh diameter of the metal grid is 1-4 mm, and the reaction template with the thickness of 1-3 mm is formed through the method in the step (2).
Further, in the step (2), the number of layers of the reaction template is selected according to the thickness requirement of the prefabricated ceramic reinforced composite layer, and the number of the layers is 1-30.
The invention has the beneficial effects that: the preparation method has simple and feasible process, controllable thickness of the reinforcing layer, suitability for casting products with various shapes, no need of special production equipment, good comprehensive performance of the prepared carbide ceramic particle reinforced steel-based surface composite material, excellent abrasion resistance, corrosion resistance and thermal fatigue resistance, and prolonged service life of the casting products.
The method is simple, convenient and feasible, the thickness of the enhancement layer is controllable, the method is suitable for casting products with various shapes, special production equipment is not needed, and the prepared carbide ceramic enhanced steel-based surface composite casting has excellent comprehensive performance and is suitable for industrial production. In particular, the fine wire mesh is melted by utilizing the heat released by the high-temperature thermal explosion reaction, so that the carbide ceramic reinforcing phase generated in situ is uniformly distributed in the ferroalloy melt and metallurgical bonding is realized, the obtained surface reinforcing layer has compact structure, controllable shape and thickness and high bonding strength with the matrix alloy, and the service performance and service life of the casting are effectively improved.
In order to improve the defects of the cast-infiltration technology, raw material powder can be prepared into separate pre-reaction pellets through a granulation technology, fine iron wires are used for isolation to form a reaction template, then molten high-temperature molten metal is used for igniting the pre-reaction pellets to carry out thermal explosion reaction, the iron wires are melted, a ceramic reinforcing phase which has no pollution on the surface, good compatibility with a substrate and high interface bonding strength is generated in situ, the ceramic reinforcing phase is diffused in the surface molten metal in a short distance and uniformly distributed in the surface molten metal, the structure of the surface reinforcing layer is compact, and finally the high-strength, high-toughness, wear-resistant, corrosion-resistant and high-temperature-resistant steel-based surface composite material casting is obtained.
Drawings
FIG. 1 is an XRD pattern of a TiC enhanced iron-based surface composite material prepared in example 1 of the present invention;
FIG. 2 is an SEM photograph of a TiC enhanced Fe-based surface composite material prepared in example 1 of the present invention.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
Firstly, uniformly mixing raw material powder, granulating, filling the raw material powder into fine iron wire grids, bonding and forming, assembling according to the shape and size of a casting product, and fixing the mixture as a pre-reaction layer at a part needing to be enhanced on the inner surface of a casting mold cavity; then pouring high-temperature molten iron (molten steel) in the casting mould, carrying out high-temperature thermal explosion reaction on the raw material powder, carrying out short-range diffusion on in-situ generated carbide ceramic particles in surface metal liquid, and simultaneously melting the wire gauze; and finally, cooling the casting to obtain the steel-based surface composite material with the carbide ceramic reinforced steel composite layer on the surface layer and the steel matrix on the core part.
A method for preparing a carbide ceramic reinforced steel-based surface composite material by thermal explosion reaction comprises the following steps:
step (1), uniformly mixing raw material powder of a prefabricated ceramic reinforced composite layer, adding a PVA solution with the mass fraction of 4-7% as a binder, and uniformly stirring; and then granulating by using a compression granulator, or crushing and sieving for granulation after compression molding by using a press to obtain a plurality of pre-reaction pellets.
And (2) uniformly filling the pre-reaction pellets into a metal grid, wherein the metal grid can be a grid made of fine iron wire. Binding the pre-reaction pellets and the metal grids to form a reaction template by using a phenolic resin alcohol solution with the mass fraction of 5-10% as a binding agent; one or more layers of the reaction templates are stacked and connected by taking phenolic resin alcohol solution with the mass fraction of 5-10% as a binder to form a pre-reaction layer; and fixing the pre-reaction layer matched with the casting in shape and size at the position of the inner surface of the cavity of the casting needing reinforcement.
And (3) pouring the steel metal liquid with the temperature of 1350-1650 ℃ into the casting cavity, so that the pre-reaction layer is subjected to high-temperature thermal explosion reaction under the high-temperature condition, the metal grid is melted, micron-level carbide ceramic particles are generated in situ, and the carbide ceramic particles are uniformly diffused in the steel metal liquid in a short distance to form a ceramic reinforced composite layer.
After the high-temperature molten metal ignites the pre-reaction layer to perform high-temperature thermal explosion reaction, spherical/nearly spherical carbide ceramic particles with the size of 1-10 microns are generated in situ, and are uniformly distributed in a surface steel matrix formed by molten and infiltrated molten metal of a wire mesh after short-distance diffusion, so that a steel-based surface composite casting with a carbide ceramic reinforced steel composite layer on the surface and a matrix in the core is finally prepared.
In some embodiments, the raw material powder is graphite powder and a metal powder, the common metal powder can be Ti powder, Zr powder, W powder, Cr powder, the mass ratio of the graphite powder and the metal powder is determined by the stoichiometric ratio of the carbide ceramic as a reaction product, and the particle size of each raw material powder is 5-100 microns.
In some embodiments, in the step (1), after the raw material powder is granulated, the pre-reaction pellets with a particle size of 1-3 mm are formed, the porosity of the pre-reaction pellets is 20-50%, the mesh diameter of the metal mesh is 1-4 mm, and the reaction template with a thickness of 1-3 mm is formed by the method in the step (2). The bonding strength of the raw material powder and the wire netting is good.
In some embodiments, the number of the reaction templates included in the pre-reaction layer is selected according to the thickness requirement of the prefabricated ceramic reinforced composite layer, and the number of the reaction templates is 1-30. The thickness, shape and size of the pre-reaction layer are determined by the casting product performance requirements, shape and size.
In the existing preparation method of the ceramic reinforced composite layer, graphite powder and metal powder in raw material powder are paved or made into precast blocks to be arranged in a casting cavity, the raw material powder is usually fine powder with the particle size of 5-100 mu m, the powder is easily dispersed by metal liquid in the process of casting metal liquid, so that the thickness of the ceramic reinforced composite layer and the particle distribution of a reinforced phase are not uniform, or the in-situ reaction process of the precast blocks is incomplete, the metal liquid is not easy to infiltrate into the interior of the precast blocks, so that the reinforced phase is not uniformly distributed in the composite layer, and the problems of air holes, impurities and the like are caused.
The method comprises the steps of fully mixing raw material powder, granulating the raw material powder to form pre-reaction pellets with uniform particle size, distributing the pre-reaction pellets in metal grids with the same pore size, forming reaction templates through bonding, stacking one or more layers of the reaction templates and bonding to form a pre-reaction layer, and finally placing the pre-reaction layer at a position, needing to be enhanced, on the inner surface of a casting cavity. The metal grid ensures that the pre-reaction pellets are uniformly distributed and are not easily dispersed by the metal liquid, thereby being beneficial to the complete reaction process and the uniform distribution of the reinforcing phase; meanwhile, after the pre-reaction pellets are subjected to thermal explosion reaction, metal grids are melted, and the formed metal liquid can fully fill the pores among the pre-reaction pellets, so that the ceramic reinforced composite layer generated after the thermal explosion reaction cannot have the problems of air holes, impurities and the like.
Example 1:
(1) the raw material powder is Ti powder (with the grain diameter of 45 microns) and graphite powder (with the grain diameter of 5 microns), and the mass ratio of the Ti powder to the graphite powder is 16: 4: mixing and stirring Ti powder and graphite powder of 1 and 4-7% PVA solution as a binder uniformly, and granulating by using a compression granulator, or crushing, sieving and granulating after compression molding by using a press to obtain raw material particles with the particle size of about 1mm and the porosity of 35%;
(2) filling the pre-reaction pellets into grids of fine wire netting with the specification of 15 meshes and the aperture of 1mm, bonding the pre-reaction pellets and the wire netting into a reaction template with the thickness of about 1mm by using 5-10% phenolic resin alcohol solution as a bonding agent, selecting a single-layer reaction template as a pre-reaction layer, and fixing the pre-reaction template at a position needing to be reinforced on the inner surface of a cavity;
(3) pouring the nodular cast iron molten metal at 1400 ℃, enabling the pre-reaction layer to perform high-temperature thermal explosion reaction at high temperature, melting the wire mesh and generating in situ approximately spherical TiC ceramic particles with the size of 1-3 microns, wherein the TiC ceramic particles are uniformly distributed in the molten metal on the surface layer; finally, the iron-based surface composite material casting with the surface layer being a TiC ceramic reinforced composite layer with the thickness of 2mm and the core being a nodular cast iron matrix is prepared.
Example 2:
(1) the raw material powder is W powder (particle size is 20 microns) and graphite powder (particle size is 5 microns), and the mass ratio of the W powder to the graphite powder is 16: 1: mixing and stirring the W powder, graphite powder and 4-7% PVA solution of 1 as a binder uniformly, and granulating by using a compression granulator, or crushing, sieving and granulating after compression molding by using a press to obtain pre-reaction pellets with the particle size of about 3mm and the porosity of 40%;
(2) filling the pre-reaction pellets into grids of fine wire netting with the specification of 5 meshes and the aperture of 3mm, bonding the pre-reaction pellets and the wire netting into a reaction template with the thickness of about 3mm by using 5-10% phenolic resin alcohol solution as a bonding agent, selecting a single-layer reaction template as a pre-reaction layer, and fixing the pre-reaction template at a position needing to be reinforced on the inner surface of a cavity;
(3) pouring high-chromium cast iron molten metal at 1550 ℃, enabling the pre-reaction layer to perform high-temperature thermal explosion reaction at high temperature, melting the wire mesh, generating WC ceramic particles with the sizes of 5-10 microns and regular shapes in situ, and uniformly distributing the WC ceramic particles in the surface molten metal; finally, the iron-based surface composite material casting with the surface layer being a WC ceramic reinforced composite layer with the thickness of 5mm and the core being a high-chromium cast iron matrix is prepared.
Example 3:
(1) the raw material powder is Ti powder (with the grain diameter of 45 microns) and graphite powder (with the grain diameter of 5 microns), and the mass ratio of the Ti powder to the graphite powder is 16: 4: mixing and stirring Ti powder, graphite powder and 4-7% PVA solution of 1 as a binder uniformly, and granulating by using a compression granulator, or crushing, sieving and granulating after compression molding by using a press to obtain pre-reaction pellets with the particle size of about 2mm and the porosity of 30%;
(2) filling the pre-reaction pellets into a grid of a fine wire gauze with the specification of 2mm of aperture, using 5-10% phenolic resin alcohol solution as a binder to bond the pre-reaction pellets and the wire gauze into a reaction template with the thickness of about 2mm, selecting 5 layers of reaction templates to assemble a cylindrical pre-reaction layer, and fixing the cylindrical pre-reaction layer at a position needing to be reinforced on the inner surface of a cavity;
(3) pouring 45# steel molten metal at 1600 ℃, enabling the pre-reaction layer to perform high-temperature thermal explosion reaction under the high-temperature condition, melting the wire mesh, generating approximately spherical TiC ceramic particles with the size of 1-5 microns in situ, and uniformly distributing the particles in the surface molten metal; finally, the steel-based surface composite material casting with the surface layer being a TiC ceramic reinforced composite layer with the thickness of 12mm and the core being a 45# steel matrix is prepared.
The product prepared in the embodiment 1 is taken as an analysis object, fig. 1 is an XRD (X-ray diffraction) spectrum of the TiC enhanced iron-based surface composite material prepared in the embodiment 1 of the invention, and a TiC ceramic enhancement layer is generated on the surface of an iron casting through thermal explosion reaction as can be seen from fig. 1; fig. 2 is an SEM photograph of the TiC reinforced iron-based surface composite material prepared in example 1 of the present invention, and it can be seen from fig. 2 that the TiC ceramic phase distribution and the particle size in the ceramic reinforcing layer prepared therefrom are uniform.
Claims (4)
1. The method for preparing the carbide ceramic reinforced steel-based surface composite material by the thermal explosion reaction is characterized by comprising the following steps of:
uniformly mixing raw material powder of a prefabricated ceramic reinforced composite layer, adding a PVA solution with the mass fraction of 4-7% as a binder, uniformly stirring, pressing and molding, crushing, sieving and granulating to obtain pre-reaction pellets;
uniformly filling the pre-reacted pellets into a metal grid, and bonding the pre-reacted pellets and the metal grid to form a reaction template by using a phenolic resin alcohol solution with the mass fraction of 5-10% as a bonding agent;
one or more layers of the reaction templates are stacked and connected by taking phenolic resin alcohol solution with the mass fraction of 5-10% as a binder to form a pre-reaction layer;
fixing the pre-reaction layer with the shape and the size matched with the casting at the position of the inner surface of the cavity of the casting needing to be enhanced;
and (3) pouring steel metal liquid with the temperature of 1350-1650 ℃ into the casting cavity, so that the pre-reaction layer is subjected to high-temperature thermal explosion reaction under the high-temperature condition, the metal grid is melted, micron-level carbide ceramic particles are generated in situ, and the carbide ceramic particles are diffused in the steel metal liquid to form a ceramic reinforced composite layer.
2. The method for preparing the carbide ceramic reinforced steel-based surface composite material by the thermal explosion reaction according to claim 1, wherein the raw material powder is graphite powder and metal powder, the mass ratio of the graphite powder to the metal powder is determined by the stoichiometric ratio of the carbide ceramic as a reaction product, and the particle size of each raw material powder is 5-100 micrometers.
3. The method for preparing the carbide ceramic reinforced steel-based surface composite material through the thermal explosion reaction according to claim 1 or 2, wherein in the step (1), the pre-reaction pellets with the grain size of 1-3 mm are formed after the raw material powder is granulated, the porosity of the pre-reaction pellets is 20-50%, the mesh diameter of the metal mesh is 1-4 mm, and the reaction template with the thickness of 1-3 mm is formed through the method in the step (2).
4. The method for preparing the carbide ceramic reinforced steel-based surface composite material through the thermal explosion reaction according to claim 3, wherein in the step (2), the number of layers of the reaction template is selected according to the thickness requirement of the prefabricated ceramic reinforced composite layer, and is 1-30.
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN1039747A (en) * | 1989-07-19 | 1990-02-21 | 浙江大学 | A kind of method that improves thickness of cast cemented alloy layer |
| US20110033772A1 (en) * | 2007-12-20 | 2011-02-10 | The Regents Of The University Of California | Sintered porous structure and method of making same |
| CN111054903A (en) * | 2019-12-27 | 2020-04-24 | 重庆罗曼新材料科技有限公司 | Wear-resistant part with space grid-shaped ceramic-metal composite layer and preparation method thereof |
| CN111455249A (en) * | 2020-03-18 | 2020-07-28 | 内蒙古科技大学 | Manganese steel-based complex-phase particle reinforced metal ceramic surface composite material, casting and manufacturing method thereof |
| CN113755737A (en) * | 2021-09-10 | 2021-12-07 | 昆明理工大学 | Double-scale particle reinforced metal matrix configuration composite material, preparation method and application |
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- 2022-05-31 CN CN202210611609.7A patent/CN114985708A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1039747A (en) * | 1989-07-19 | 1990-02-21 | 浙江大学 | A kind of method that improves thickness of cast cemented alloy layer |
| US20110033772A1 (en) * | 2007-12-20 | 2011-02-10 | The Regents Of The University Of California | Sintered porous structure and method of making same |
| CN111054903A (en) * | 2019-12-27 | 2020-04-24 | 重庆罗曼新材料科技有限公司 | Wear-resistant part with space grid-shaped ceramic-metal composite layer and preparation method thereof |
| CN111455249A (en) * | 2020-03-18 | 2020-07-28 | 内蒙古科技大学 | Manganese steel-based complex-phase particle reinforced metal ceramic surface composite material, casting and manufacturing method thereof |
| CN113755737A (en) * | 2021-09-10 | 2021-12-07 | 昆明理工大学 | Double-scale particle reinforced metal matrix configuration composite material, preparation method and application |
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