CN115283607A - Casting reinforcing coating material and application thereof - Google Patents
Casting reinforcing coating material and application thereof Download PDFInfo
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- CN115283607A CN115283607A CN202210939035.6A CN202210939035A CN115283607A CN 115283607 A CN115283607 A CN 115283607A CN 202210939035 A CN202210939035 A CN 202210939035A CN 115283607 A CN115283607 A CN 115283607A
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- 238000005266 casting Methods 0.000 title claims abstract description 156
- 239000011248 coating agent Substances 0.000 title claims abstract description 156
- 239000000463 material Substances 0.000 title claims abstract description 119
- 230000003014 reinforcing effect Effects 0.000 title claims abstract description 21
- 239000000843 powder Substances 0.000 claims abstract description 139
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 118
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- 239000002245 particle Substances 0.000 claims abstract description 45
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 37
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- 238000002485 combustion reaction Methods 0.000 abstract description 12
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 abstract description 2
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- 238000005496 tempering Methods 0.000 description 8
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- LDXJRKWFNNFDSA-UHFFFAOYSA-N 2-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)-1-[4-[2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidin-5-yl]piperazin-1-yl]ethanone Chemical compound C1CN(CC2=NNN=C21)CC(=O)N3CCN(CC3)C4=CN=C(N=C4)NCC5=CC(=CC=C5)OC(F)(F)F LDXJRKWFNNFDSA-UHFFFAOYSA-N 0.000 description 1
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- 244000035744 Hura crepitans Species 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- AFCARXCZXQIEQB-UHFFFAOYSA-N N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]-2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidine-5-carboxamide Chemical compound O=C(CCNC(=O)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)N1CC2=C(CC1)NN=N2 AFCARXCZXQIEQB-UHFFFAOYSA-N 0.000 description 1
- 241000227425 Pieris rapae crucivora Species 0.000 description 1
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- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/10—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on titanium carbide
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention provides a casting reinforcing coating material which comprises the following components in parts by mass: 20-70 parts of titanium powder, 3-20 parts of graphite powder, 3-30 parts of tungsten carbide powder and 3-80 parts of mixed metal powder; wherein the particle size of the titanium powder is 200-300 meshes, the particle size of the graphite powder is 200-300 meshes, the particle size of the tungsten carbide powder is 140-325 meshes, and the particle size of the mixed metal powder is 100-200 meshes. And placing the casting reinforcing coating material in the part to be reinforced in the shell in advance, and pouring the casting reinforcing coating material with high-chromium molten iron after die combination. The casting reinforced coating material is contacted with high-chromium molten iron and then undergoes self-propagating combustion, wherein titanium element is converted into titanium carbide to form a TiC-based high-chromium cast-infiltration alloy phase; the molten iron is cast and infiltrated to generate superfine holes, and TiC particles are distributed in the superfine holes, so that the structure of a cast and infiltrated part is more compact and complete, the abrasion resistance and high toughness of a matrix are ensured, and the strength of a product is obviously stronger than that of common high-chromium cast iron.
Description
Technical Field
The invention relates to the technical field of local reinforcement of metal-based composite coatings, in particular to a casting reinforced coating material and application thereof.
Background
High-chromium cast iron is short for high-chromium white wear-resistant cast iron and is a wear-resistant material with excellent performance and special attention; it has much higher wear resistance than alloy steel, much higher toughness and strength than common white cast iron, and simultaneously has good high temperature resistance and corrosion resistance, convenient production and moderate cost, thus being praised as one of the most excellent wear-resistant materials.
With the further development of the technology, special working conditions of the medium put higher demands on the wear resistance and the service life of the transmission part. At present, the service life problem of high-chromium iron castings becomes a great problem for restricting continuous transmission of equipment, which shows that the high-chromium iron as a fourth-generation wear-resistant cast iron has technical bottlenecks and needs to be upgraded. Meanwhile, the material is saved, and the lightweight is ensured to become a new development trend of wear-resistant materials. The composite metal matrix made of the light coating material becomes the mainstream development idea of material research and development personnel in recent years.
Disclosure of Invention
In order to solve the problems in the prior art, the invention aims to provide a casting reinforced coating material capable of effectively improving the wear resistance and toughness of iron castings and application thereof.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
a casting reinforcing coating material comprises the following components in parts by mass: 20-70 parts of titanium powder, 3-20 parts of graphite powder, 3-30 parts of tungsten carbide powder and 3-80 parts of mixed metal powder; wherein the particle size of the titanium powder is 200-300 meshes, the particle size of the graphite powder is 200-300 meshes, the particle size of the tungsten carbide powder is 140-325 meshes, and the particle size of the mixed metal powder is 100-200 meshes; preferably comprises the following components in parts by mass: 30-60 parts of titanium powder, 5-15 parts of graphite powder, 10-25 parts of tungsten carbide powder and 15-50 parts of mixed metal powder; wherein the particle size of the titanium powder is 300 meshes, the particle size of the graphite powder is 300 meshes, the particle size of the tungsten carbide powder is 325 meshes, and the particle size of the mixed metal powder is 100-200 meshes.
The mixed metal powder comprises the following components in percentage by mass: 0 to 60wt% of nickel powder, 0 to 10wt% of molybdenum powder, 0 to 10wt% of copper powder, 0 to 60wt% of cobalt powder, 0 to 10wt% of silicon powder, 0 to 10wt% of rare earth powder, 0 to 5wt% of magnesium powder, 0 to 5wt% of boron, and the balance of iron powder; preferably comprises the following components in percentage by mass: 0-60wt% of nickel powder, 0-6 wt% of molybdenum powder, 5-10 wt% of copper powder, 2-60 wt% of cobalt powder, 1-3 wt% of silicon powder, 1-3 wt% of rare earth powder, 1-5 wt% of magnesium powder, 0-3wt% of boron and the balance of iron powder.
The application of the casting reinforcing coating material comprises the steps of placing the casting reinforcing coating material in a part to be reinforced in a shell in advance, and pouring the casting reinforcing coating material with high-chromium molten iron after die combination; the casting reinforced coating material is contacted with high-chromium molten iron to generate self-propagating reaction to form a high-strength high-chromium cast-infiltration alloy phase.
When the part of the casting to be enhanced is positioned on the surface of the casting, a pre-coating method is adopted for preparation; when the part of the casting to be enhanced is positioned in the casting, the prefabricated block method is adopted for preparation.
The pre-coating method specifically comprises the following steps:
A. adding a proper amount of binder and clear water into the powdery coating material, mixing and stirring into paste;
B. directly coating the paste on an area needing to be reinforced on a precoated sand shell/mold core, wherein the coating thickness is 1mm to 30mm;
C. coating a layer of sand-sticking-preventing coating on the area of the precoated sand shell/mold core surface which is not coated with the paste, then heating at low temperature, and drying the paste and the sand-sticking-preventing coating;
D. closing the film-coated sand mold shell, and pouring by using molten high-chromium molten iron to obtain a green body;
E. and (3) finishing the green blank, performing austenite destabilization heat treatment, cooling, and performing sand blasting, finishing and polishing to obtain the high-strength high-chromium casting.
In the step A, the used binder is polyvinyl alcohol aqueous solution with the mass concentration of 1.2%, and the mass ratio of the coating material, the binder and the water is 1:1% -2%: 30% -40%.
The precast block method specifically comprises the following steps:
A. adding a proper amount of lubricant into the powdery coating material, and mixing and stirring the mixture into viscous powder;
B. filling the viscous powder into a metal mold, forming the viscous powder into a prefabricated block by vibration pressure, and drying the prefabricated block;
C. fixing the prefabricated block at the position of the film-coated sand mold shell to be reinforced, and drying the mold shell;
D. closing the film-coated sand mold shell, and pouring by using molten high-chromium molten iron to obtain a green body;
E. and (3) after the green body is trimmed, carrying out austenite destabilization heat treatment, cooling, and then carrying out sand blasting, trimming and polishing to obtain the high-strength high-chromium casting.
In the step A, the used lubricant is stearic acid or paraffin, and the feeding mass ratio of the coating material to the lubricant is 1:3% -8%; and in the step B, the pressing pre-pressure is not less than 15 tons.
Due to the adoption of the technical scheme, the invention has the technical progress that:
the invention provides a casting reinforcing coating material, which is formed by mixing a plurality of metal powder and non-metal powder according to a certain proportion, wherein the coating material is contacted with high-chromium molten iron and then undergoes self-propagating reaction combustion, and titanium element is converted into titanium carbide to form a TiC ceramic phase-based high-chromium cast infiltration alloy phase; the molten iron is cast and infiltrated to generate superfine holes, and TiC ceramic phase particles are distributed in the superfine holes, so that the structure of the cast and infiltrated part is more compact and complete, the abrasion resistance and high toughness of the matrix are ensured, and the strength of the product is obviously stronger than that of common high-chromium cast iron.
According to the invention, titanium powder, graphite powder and tungsten carbide powder are main combustion components of a self-propagating reaction, and through reasonable matching of the three components, stable ceramic phase particles with proper particle size are formed after combustion and are just filled into holes of a high-chromium casting, so that the compactness of a matrix is improved; if the proportion of the titanium powder, the graphite powder or the tungsten carbide powder is changed, the phenomenon of insufficient combustion occurs, for example, the titanium powder, the graphite powder or the tungsten carbide powder which are not completely reacted float on the surface of a casting, a ceramic phase formed by combustion is not stable enough, the surface of the casting has defects or overburning, a matrix structure is not compact enough, and the like, the strength of the casting is affected, and even the extreme conditions that the body property is lost due to loose reinforced parts and the strength is lower than that of an iron casting may occur.
Mixed metal powders are used to assist in increasing the strength of the casting. The nickel powder, the cobalt powder, the molybdenum powder, the copper powder and the silicon powder in the metal powder are combined through smelting to form a connecting intermediate phase of a raw material matrix and a ceramic phase, so that the connecting strength between the matrix and the ceramic phase is improved, and the compactness of the matrix is further improved; if the proportion is insufficient, a loose structure is generated, otherwise, excessive precipitation precipitates are generated, and the connection strength is reduced. The rare earth powder has the functions of deslagging and degassing in the combustion process, serves as a refining agent in the self-propagating reaction process, and generates impurities when the rare earth powder is insufficient or excessive; the magnesium powder is a combustion improver of self-propagating reaction, and the boron powder can form a floating glass phase to protect the surface of a casting which is over-sintered.
In practical application, the invention can select a pre-coating method or a precast block method for casting according to different positions and shapes of the part to be reinforced of the casting, and has flexible and variable application modes and strong practicability. During pouring, the coating material and the molten iron are fully fused by controlling the liquid level rising speed to be higher than the reaction speed.
The coating material disclosed by the invention is used for reinforcing castings, can realize batch production by means of tools, and has good coating stability and good industrial popularization prospect.
Drawings
FIG. 1 is a schematic structural view of a slurry pump jacket according to example 9;
FIG. 2 isbase:Sub>A schematic sectional view taken along line A-A in FIG. 1;
FIG. 3 is a schematic structural view of an elbow pipe according to embodiment 10;
fig. 4 is a schematic front view of the wear plate according to embodiment 11;
fig. 5 is a schematic top view of the wear plate according to embodiment 11.
Detailed Description
The present invention will be described in detail below.
A casting reinforcing coating material comprises the following components in parts by mass: 20-70 parts of titanium powder, 3-20 parts of graphite powder, 3-30 parts of tungsten carbide powder and 3-80 parts of mixed metal powder; wherein the particle size of the titanium powder is 200-300 meshes, the particle size of the graphite powder is 200-300 meshes, the particle size of the tungsten carbide powder is 140-325 meshes, and the particle size of the mixed metal powder is 100-200 meshes.
Preferably, the coating material comprises the following components in parts by mass: 30-60 parts of titanium powder, 5-15 parts of graphite powder, 10-25 parts of tungsten carbide powder and 15-50 parts of mixed metal powder; wherein the particle size of the titanium powder is 300 meshes, the particle size of the graphite powder is 300 meshes, the particle size of the tungsten carbide powder is 325 meshes, and the particle size of the mixed metal powder is 100-200 meshes.
The mixed metal powder in the coating material is formed by ball-milling and mixing a plurality of metal powders, and specifically comprises the following components in percentage by mass: 0 to 60wt% of nickel powder, 0 to 10wt% of molybdenum powder, 0 to 10wt% of copper powder, 0 to 60wt% of cobalt powder, 0 to 10wt% of silicon powder, 0 to 10wt% of rare earth powder, 0 to 5wt% of magnesium powder, 0 to 5wt% of boron and the balance of iron powder;
preferably comprising: 0-60wt% of nickel powder, 0-6wt% of molybdenum powder, 5-10 wt% of copper powder, 2-60 wt% of cobalt powder, 1-3 wt% of silicon powder, 1-3 wt% of rare earth powder, 1-5 wt% of magnesium powder, 0-3 wt% of boron and the balance of iron powder.
Most preferably comprises: 30-50 wt% of nickel powder, 0-3 wt% of molybdenum powder, 5-8 wt% of copper powder, 3-20 wt% of cobalt powder, 1-3 wt% of silicon powder, 1-3 wt% of rare earth powder, 1-1.5 wt% of magnesium powder, 0-3 wt% of boron and the balance of iron powder.
The high-chromium cast iron belongs to ferrous metal, is different from nonferrous metal copper-based alloy with higher ductility and fatigue resistance, has low as-cast toughness and is a brittle wear-resistant material, so that the addition of elements cannot influence the high-chromium cast iron on the selection of coating materials aiming at the characteristics of the high-chromium cast iron. For example, excessive boron element is introduced into a boron-based ceramic phase base, so that the toughness of a metallurgical bonding layer is reduced, and the cracking instability is improved; the risk of hydrogen pore products is increased by the introduction of aluminum powder, the borax has poor solubility, more slag is introduced, and the like.
The preparation method of the casting reinforced coating material comprises the following steps:
s1, weighing nickel powder, molybdenum powder, copper powder, cobalt powder, silicon powder, rare earth powder, magnesium powder, boron powder and iron powder according to a proportion, adding the materials into a ball mill, and grinding and mixing for 1 to 24h to obtain mixed metal powder with the average particle size of 100-200 meshes;
s2, weighing titanium powder, graphite powder, tungsten carbide powder and mixed metal powder in proportion, adding the titanium powder, the graphite powder, the tungsten carbide powder and the mixed metal powder into a ball mill, and grinding and mixing for 1-24h until the mixture is uniform to obtain a finished coating material.
The casting reinforcing coating material is mainly applied to the reinforcement of high-chromium castings. Specifically, when sand casting is carried out, the reinforcing coating material is firstly placed in a part to be reinforced in a shell in advance, and then mould closing and high-chromium molten iron pouring are carried out. When pouring, the molten iron is contacted with the reinforced coating material, the temperature of the molten iron initiates the self-propagating reaction of the coating material, namely Ti + C = TiC, and a TiC-based high-chromium cast infiltration alloy phase is formed; meanwhile, other metal components in the coating material also participate in the reaction and form a transition-state intermediate phase, and the existence of the intermediate phase effectively strengthens the bonding strength between the alloy phase and the matrix; the strength and hardness of the high-chromium cast-infiltration alloy phase are obviously stronger than those of a common high-chromium cast iron phase, and the bonding of a reinforced part is compact and complete.
The casting process is preferably a coated sand shell casting.
When molten iron is poured, a medium-frequency induction furnace is generally adopted to melt high-chromium molten iron, and rapid pouring is completed according to a specified temperature. After finishing and polishing, the casting is subjected to high-temperature hardening treatment and tempering, the hardness of the non-cast infiltration material reaches about 58HRc, the hardness of a reinforced area reaches more than 65HRc, and the reinforced part is tightly combined and has complete tissues.
Further, the preparation method of the reinforced casting comprises a precoating method and a precast block method, and two different using methods are described in detail below.
1. Precoating method
The pre-coating method is mainly used for the condition that the surface of a casting (such as a working surface of the casting) needs to be strengthened, and the coating material is pre-coated on the surface of a shell/core corresponding to the area of the casting needing to be strengthened, so that self-propagating reaction occurs on the surface of the casting.
Specifically, the powdery coating material, the binder and clear water are mixed and stirred into paste, then the paste is uniformly coated on the part needing to be reinforced on the surface of the precoated sand shell/mold core in equal parts according to the local surface profile of the casting, and after the paste is completely dried, the mold is closed for molten iron pouring.
The method for preparing the high-strength high-chromium casting by using the pre-coating method specifically comprises the following steps of:
A. adding a proper amount of binder and clear water into the powdery coating material, mixing and stirring into paste;
B. directly coating the paste on an area needing to be reinforced on a precoated sand shell/mold core, wherein the coating thickness is 1mm to 30mm;
C. coating a layer of sand-sticking-preventing coating on the area of the precoated sand shell/mold core surface which is not coated with the paste, then heating at low temperature, and drying the paste and the sand-sticking-preventing coating;
D. closing the film-coated sand mold shell, and pouring by using molten high-chromium molten iron to obtain a green body;
E. and (3) finishing the green blank, performing austenite destabilization heat treatment, cooling, and performing sand blasting, finishing and polishing to obtain the high-strength high-chromium casting.
In the step A, the step A is carried out,
the adhesive is polyvinyl alcohol aqueous solution with the mass concentration of 1.2%; the mass ratio of the coating material, the binder and the water is 1 (1-2%) (30-40%), preferably 1 (1-1.2%) (30-40%). The coating material is blended into a paste with moderate viscosity by adding a proper amount of the binder and water, so that the coating material has good coating property and adhesion and can be firmly adhered to the surface of the precoated sand mold shell/core. The addition amount of water is related to the required coating thickness, and the coating thickness is determined by the strength requirement of the required working surface; the thickness of the required coating layer is small, the water adding amount can be increased, and the paste is thinner; the coating layer is thick, so that less water needs to be added, the paste is viscous, and the forming is convenient.
In the step B, the coating thickness of the paste is preferably from 3mm to 20mm, the coating thickness is adjusted according to different local required strength, and the coating thickness is properly thickened along with the increase of the required strength. In the coating process, in order to ensure the coating area and the coating thickness of the paste and increase the operation convenience of the coating process, a limiting enclosure frame with proper height can be installed in the circumferential direction of a region to be strengthened, the height of the limiting enclosure frame can be set to be the same as the thickness of the paste to be coated, and the paste can be directly filled in the limiting enclosure frame. The limiting enclosure frame can be formed by enclosing the ending of the battens and is adhered to the surface of the shell; after the coating is finished, the limiting enclosure frame is removed, and the detached limiting enclosure frame can be repeatedly used.
In the step C, the sand adhesion preventing paint is generally an alcohol-based sand adhesion preventing paint, such as a zircon powder alcohol-based paint for sand adhesion preventing cast steel, and the coating thickness of the sand adhesion preventing paint is 0.5mm to 1mm. After the anti-sand coating is coated, the shell/core is dried by an alcohol blast burner or other modes, and then the subsequent die assembly and pouring operation is carried out to ensure the smoothness of the surface of the casting.
The local strengthening area coated with the coating paste body can be free from being coated with the anti-sticking silanol-based coating in order to ensure gas emission.
In the step D, smelting the high-chromium molten iron by preferably adopting a medium-frequency induction furnace. When high-chromium molten iron is poured, the optimal pouring temperature interval is selected according to the liquid level rising speed of more than 3.5mm/s, and the full casting-infiltration combination is ensured.
The heat treatment method in the step E may be selected according to the performance requirements of the high chromium casting, and this technical feature is not the invention point of the present invention, so it is not limited in detail herein.
2. Precast block method
The precast block method is mainly used for the condition that the interior of a casting cavity needs to be reinforced, and a coating material is made into a three-dimensional precast block and is fixed in a shell, so that a self-propagating reaction during pouring occurs along the edge of the precast block and in the interior of a casting.
Specifically, firstly, a coating material and a lubricant are mixed into viscous powder, a prefabricated block is manufactured through mold vibration pressure, the prefabricated block is fixed at a position needing to be reinforced in a shell in advance, and after drying, mold assembly and molten iron pouring are carried out.
The method for preparing the high-strength high-chromium casting by using the precast block method specifically comprises the following steps of:
A. adding a proper amount of lubricant into the powdery coating material, and mixing and stirring the mixture into viscous powder;
B. filling the viscous powder into a metal mold, forming the viscous powder into a prefabricated block by vibration pressure, and drying the prefabricated block;
C. fixing the prefabricated block at the position of the film-coated sand mold shell to be reinforced, and drying the mold shell;
D. closing the film-coated sand mold shell, and pouring by using molten high-chromium molten iron to obtain a green body;
E. and (3) finishing the green blank, performing austenite destabilization heat treatment, cooling, and performing sand blasting, finishing and polishing to obtain the high-strength high-chromium casting.
In the step A, the adopted lubricant is stearic acid or paraffin, and the feeding mass ratio of the coating material to the lubricant is 1:3% to 8%, preferably 1:4% to 6%, most preferably 1.
In the step (B), the step (A),
the prefabricated block is generally a cuboid with the thickness of 2mm-100mm, preferably a cuboid with the thickness of 2mm-40mm, and corners of the prefabricated block are preferably rounded corners in smooth transition. When the casting is in a special shape, the shape of the precast block can be adjusted according to the actual shape in order to ensure that the strength of each part of the casting is uniform.
When the precast block is prepared, the prepressing force of pressing is not less than 15 tons, and the precast block is ensured to be compact and uniform.
In the step C, the fixing mode of the precast block comprises two modes of adhesion fixing and mechanical fixing. And the adhesion fixation means that the prefabricated block is adhered to the surface of the appointed strengthening area after the surface of the appointed strengthening area is coated with PVA water solution, and then the prefabricated block is returned to the furnace for drying. The mechanical fixing means that the prefabricated block is fixedly connected with the shell through a positioning pin; the positioning pins are pre-pressed in the prefabricated blocks.
In the step D, smelting the high-chromium molten iron by preferably adopting a medium-frequency induction furnace. When high-chromium molten iron is poured, the optimal pouring temperature interval is selected according to the liquid level rising speed of more than 3.5mm/s, and the full casting-infiltration combination is ensured.
In the step E, after the green compact is heat-treated and cooled, the strength of the matrix reaches the peak value, and the specific method of the heat treatment can be selected according to the performance requirements of the high-chromium casting, and the technical characteristics are not the invention point of the present invention, so that the details are not limited herein.
The invention is further illustrated by the following examples.
In the following examples, the raw material sources and specifications used were:
the other raw materials are all conventional raw materials sold in markets.
Example 1
A casting reinforcing coating material comprises the following components in parts by mass: 30 parts of titanium powder, 15 parts of graphite powder, 25 parts of tungsten carbide powder and 50 parts of mixed metal powder; wherein the particle size of the titanium powder is 200 meshes, the particle size of the graphite powder is 200 meshes, the particle size of the tungsten carbide powder is 325 meshes, and the particle size of the mixed metal powder is 200 meshes.
The mixed metal powder comprises the following components in percentage by mass: 50wt% of nickel powder, 3wt% of molybdenum powder, 5wt% of copper powder, 3wt% of cobalt powder, 3wt% of silicon powder, 3wt% of rare earth powder, 1.5wt% of magnesium powder and the balance of iron powder.
The preparation method of the casting reinforced coating material comprises the following steps:
s1, weighing nickel powder, molybdenum powder, copper powder, cobalt powder, silicon powder, rare earth powder, magnesium powder, boron powder and iron powder in proportion, adding the weighed materials into a ball mill, and grinding and mixing for 20 hours to obtain mixed metal powder with the average particle size of 200 meshes;
s2, weighing titanium powder, graphite powder, tungsten carbide powder and mixed metal powder in proportion, adding the weighed materials into a ball mill, and grinding and mixing for 15 hours until the materials are uniformly mixed to obtain a finished product of the coating material.
Examples 2 to 8
Examples 2 to 8 are product examples of the casting reinforcing coating material of the invention, and examples 2 to 8 comprise the following components in parts by mass:
examples 2-8 mixed metal powders for use in coating materials include, in mass percent:
the preparation method of the coating materials of the embodiments 2 to 8 is basically the same as that of the coating material of the embodiment 1.
To further verify the effect of the coating material of the present invention, comparative examples were listed for comparative verification.
Comparative example 1
Comparative example 1 based on example 1, only the difference compared to example 1 is: the titanium powder content is different. The titanium powder contents in comparative examples 1-1 and 1-2 were out of the upper and lower limits of the range defined in the present invention, respectively.
Comparative example 2
Comparative example 2 based on example 1, the only difference compared to example 1 is: the graphite powder content is different. The graphite powder contents in comparative examples 2-1 and 2-2 are out of the upper limit and the lower limit of the range defined in the present invention, respectively.
Comparative example 3
Comparative example 3 is based on example 1 and differs from example 1 only in that: the tungsten carbide powder content is different. The tungsten carbide powder contents in comparative examples 3-1 and 3-2 are out of the upper limit and the lower limit of the range defined in the present invention, respectively.
Comparative example 4
Comparative example 4 based on example 1, the only difference compared to example 1 is: the mixed metal powders vary in content. The contents of the mixed metal powders in comparative examples 4-1 and 4-2 are out of the upper and lower limits of the range defined in the present invention, respectively.
Comparative examples 5 to 8
Comparative examples 5 to 8 are based on example 1, and differ from example 1 only in that: the mixed metal powders have different component contents.
Casting tests were carried out on the products of examples 1 to 8 and comparative examples 1 to 8. The concrete pouring steps are as follows:
a. mixing 120g of coating material, 30g of polyvinyl alcohol aqueous solution with the mass concentration of 1.2wt% and 10g of water, and stirring into paste;
b. taking a rectangular sand mold, and coating the paste on one side of the sand mold, wherein the coating thickness is 10mm;
c. coating zircon powder alcohol-based paint for sand-sticking-resistant cast steel on the surface area of the mould shell except the paste coating, coating the zircon powder alcohol-based paint with the thickness of 0.5mm, baking the zircon powder alcohol-based paint for 15min by using an alcohol burner, and then placing the zircon powder alcohol-based paint into a tempering furnace along with the mould for heat preservation at 200 ℃ for 5h to 7h to ensure that the sand mould is completely dried;
d. closing the film-coated sand mold shell, and preparing high-chromium molten iron for pouring;
high-chromium molten iron is proportioned according to the standard BTMCr27 component, a medium-frequency induction furnace is adopted for smelting, the pouring temperature is 1530-1580 ℃, a bottom pouring mode is adopted for pouring, in order to avoid scouring a coating, an ingate is along the tangential direction of a guard plate, and the rising speed of the pouring liquid level is controlled to be more than 3.5 mm/s; when pouring, the coating material gradually permeates into the high-chromium molten iron, and the high-temperature molten iron triggers titanium powder to generate a self-propagating effect to form a TiC ceramic phase-based high-chromium cast-infiltration alloy phase;
after the pouring is finished, cooling, opening the box and removing sand to obtain a blank piece;
e. and (3) after the green body is trimmed, carrying out austenite destabilization heat treatment and tempering treatment, and carrying out sand blasting and polishing on the obtained casting to obtain the casting.
The hardness of the obtained casting is tested by a handheld portable hardness tester, and the test data are shown in the following table.
As can be seen from the casting test data of the embodiments 1 to 8, after the coating material is adopted, the appearance of the high-chromium iron casting is basically smooth and flat, the Rockwell hardness of the high-chromium iron casting is obviously improved compared with that of the casting which is not strengthened, the Rockwell hardness of the high-chromium iron casting which is not strengthened is 59HRC, the average Rockwell hardness of the castings of the eight embodiments is 67HRC, and the improvement effect is obvious.
The comparison of the comparative examples 1-1 and 1-2 shows that the excessive content of the titanium powder can cause incomplete combustion reaction, the titanium powder floats on the surface of a casting in a block shape, the reinforced part is loose, the ceramic phase is unstable, and the hardness cannot be detected. Too little titanium powder content can also result in incomplete self-propagating reaction, insufficiently compact structure and low casting hardness. The hardness of the casting of comparative example 1-2, which was 52.2 lower than the hardness 59 of the unreinforced high chromium iron casting, demonstrated that the casting had a very loose, less dense texture, lost bulk properties at the joints, and was less hard than the high chromium iron casting.
The comparison of the comparative example 2-1 and the comparative example 2-2 shows that the excessive content of the graphite powder can influence the self-propagating reaction effect, so that the structure is obviously not compact enough, and the casting hardness is low; too little graphite powder content can result in incomplete self-propagating reaction, unstable ceramic phase and incapability of detecting the hardness of a casting.
The comparison of the comparative example 3-1 and the comparative example 3-2 shows that the excessive content of the tungsten carbide powder can cause obvious defects on the surface of a casting and can not detect the hardness of the casting; the normal operation of the self-propagating reaction is influenced by the too low content of the tungsten carbide powder, the local over-burning phenomenon is obvious, and the hardness of the casting is low.
Comparative examples 4-1 and 4-2 were made to change the content of the mixed metal powder, which is mainly used to assist in increasing the strength of the castings, and the amount of the mixed metal powder has a significant effect on the hardness of the castings. As can be seen by comparison, the excessive content of the mixed metal powder can cause more surface pore defects and poor hardness, and the detection cannot be carried out; when the content of the mixed metal powder is too small, the bonding between the ceramic phase and the matrix is poor, and the hardness of the strengthened portion cannot be detected.
Comparative examples 5 to 8 change the component content in the mixed metal powder, and the comparison shows that when the content of one or more components in the mixed metal powder exceeds the standard, the overall hardness of the casting is affected, defects such as metallurgical bonding defects, metal precipitation precipitates, slag on the surface, pores in the interior, or multiple cold cracks occur, the connection strength between the matrix and the ceramic phase is affected, and the casting cannot be reinforced. It is thus demonstrated that the mixed metal powder itself is a whole, wherein the adjustment of the amounts of the components has a direct correlation to the strength of the final casting.
Example 9
This example is an application example of the precoating method of the coating material of the present invention, and is used for casting the flow passage components (protective plate, sheath, etc.) of slurry pumps.
The total amount of the used coating material is 12kg, and the coating material is prepared by ball milling and mixing 7kg of Ti powder with 300 meshes, 1.5kg of graphite powder with 300 meshes, 1kg of WC powder with 325 meshes and 2.5kg of mixed metal powder with 200 meshes.
Wherein, mixed metal powder component + includes: 50wt% of nickel powder, 3wt% of molybdenum powder, 3wt% of silicon powder, 3wt% of rare earth powder, 1.5wt% of magnesium powder, 5wt% of copper powder, 3wt% of cobalt powder and the balance of iron powder.
The preparation method of the coating material comprises the following steps:
s1, weighing nickel powder, molybdenum powder, copper powder, cobalt powder, silicon powder, rare earth powder, magnesium powder and iron powder in proportion, pouring the weighed materials into a ball mill, and grinding and mixing the materials for 15 hours to obtain mixed metal powder with the average particle size of 200 meshes;
s2, weighing titanium powder, graphite powder, tungsten carbide powder and mixed metal powder in proportion, pouring the mixture into a ball mill, and grinding and mixing for 20 hours to obtain the coating material.
The specific steps of using the pre-coating method are as follows:
A. mixing 12kg of coating material, 3kg of polyvinyl alcohol aqueous solution with the mass concentration of 1.2wt% and 1kg of water, and stirring the mixture into paste;
B. fixing a wooden limiting enclosure frame in a region (namely an original volatile effect region of an overflowing component) which is specified by a film-coated sand mold (a slurry pump, a guard plate and other overflowing component molding) and needs to be strengthened, uniformly coating the prepared paste in the limiting enclosure frame, wherein the coating thickness is 10mm, the coating boundary is in smooth transition, and scraping and finishing redundant paste; then removing the limiting surrounding frame, and finishing the smooth transition of the edge of the paste;
C. coating zircon powder alcohol-based paint for sand-sticking-resistant cast steel on the surface area of the mould shell except the paste coating, coating the zircon powder alcohol-based paint with the thickness of 0.5mm, baking the zircon powder alcohol-based paint for 15min by using an alcohol burner, and then placing the zircon powder alcohol-based paint into a tempering furnace along with the mould for heat preservation at 200 ℃ for 5h to 7h to ensure that the sand mould is completely dried;
D. closing the film-coated sand mold shell, and preparing high-chromium molten iron for pouring;
high-chromium molten iron is mixed according to standard BTMCr27 components, a medium-frequency induction furnace is adopted for smelting, the casting temperature is 1530-1580 ℃, a bottom pouring mode is adopted for casting, and in order to avoid coating erosion, an ingate is controlled to be more than 3.5mm/s along the tangential direction of a guard plate, and the rising speed of the casting liquid level is controlled; when pouring, the coating material gradually permeates into the high-chromium molten iron, and the high-temperature molten iron triggers titanium powder to generate a self-propagating effect to form a TiC ceramic phase-based high-chromium cast-infiltration alloy phase;
after the pouring is finished, cooling, opening the box and removing sand to obtain a blank piece;
E. and (3) after the green body is trimmed, carrying out austenite destabilization heat treatment and tempering treatment, and carrying out sand blasting and polishing on the obtained casting to obtain a casting finished product. The surface strengthening area in the finished casting product is provided with a casting and infiltration coating with the thickness of 10mm-15mm.
And (3) polishing the cast-infiltration bonding layer until the roughness is Ra0.8, wherein no obvious scratch or burn is formed on the surface, and testing by using a portable Richter hardness tester to obtain a casting finished product with the hardness of 67HRC.
The X-ray is adopted to detect the flaw of the casting, the defects of pinholes, shrinkage cavities, looseness and the like do not exist in the casting and the strengthening layer, and the compactness is good.
Comparative example 9
Comparative example 9 is a comparative example to example 9, cast directly with high chrome iron water without coating strengthening. The composition of the high chromium molten iron used, the casting control parameters and the green body heat treatment step were the same as in step D and step E of example 9.
The working surface is polished to the roughness Ra0.8, no obvious scratch and burn are caused on the surface, and the hardness of the obtained casting finished product is 58.2HRC by using a portable Richter hardness tester for detection.
Compared with the casting of the comparative example 9, the casting of the example 9 reinforced by the material of the invention has the hardness improved by 8.8HRC and remarkable effect.
Example 10
This example is an application example of the prefabricated block method for coating material of the present invention to strengthen the coating of the flow passage components of the elbow.
In this example, 4.5kg of a coating material was used, which was prepared by mixing 2.5kg of 300 mesh Ti powder, 0.5kg of 300 mesh graphite powder, 0.5kg of 325 mesh WC powder, and 1kg of 200 mesh mixed metal powder.
Wherein, mixed metal powder component includes: 50wt% of nickel powder, 3wt% of boron powder, 1wt% of rare earth powder, 3wt% of silicon powder, 1.5wt% of magnesium powder, 5wt% of copper powder, 3wt% of cobalt powder and the balance of iron powder.
The preparation method of the coating material comprises the following steps:
s1, weighing nickel powder, boron powder, silicon powder, magnesium powder, iron powder, copper powder, cobalt powder and iron powder according to a proportion, pouring the weighed materials into a ball mill, and grinding and mixing for 20 hours to obtain mixed metal powder with the average particle size of 300 meshes;
s2, weighing titanium powder, graphite powder, tungsten carbide powder and mixed metal powder in proportion, pouring the mixture into a ball mill, and grinding and mixing for 12 hours to obtain the coating material.
The concrete steps of using the prefabricated block method are as follows:
A. adding 50g of stearic acid into 4.5kg of coating material, and mixing and stirring the mixture into viscous powder;
B. filling the viscous powder into a metal mold, forming the viscous powder into a prefabricated block by vibration pressure, and drying a wet product of the prefabricated block in a tempering furnace at 200 ℃ for 1h for shaping;
C. coating the surface of the designated area to be reinforced of the coated sand mold with a PVA aqueous solution (solute PVA and solvent water are dissolved according to the mass ratio of 1;
D. combining the coated sand molds, placing the combined coated sand molds in a vacuum sand box, and pouring high-chromium cast iron molten iron to finish casting the bent pipe;
smelting high-chromium molten iron by adopting a medium-frequency induction furnace, wherein the pouring temperature is 1530-1580 ℃, the coating material gradually permeates into the high-chromium molten iron, and the high-temperature molten iron causes titanium powder to generate a self-propagating effect to form a TiC-based high-chromium cast-infiltration alloy phase;
after the pouring is finished, cooling and opening the box to obtain a raw blank;
E. and (3) burying sand in the green body of the bent pipe casting, standing for 2h, cooling to room temperature, taking out the bent pipe casting, carrying out sand blasting treatment, carrying out tempering treatment once as soon as possible, and finishing and polishing the surface of the casting after tempering treatment to obtain a finished product of the bent pipe casting.
And polishing the cast-infiltration bonding layer until the roughness is Ra0.8, wherein no obvious scratch or burn is formed on the surface, and testing by using a portable Richter hardness tester to obtain the finished product of the bent pipe casting with the hardness of 69HRC.
The X-ray is adopted to detect the flaw of the casting, so that the inner part of the casting and the strengthening layer have no defects of pinholes, shrinkage cavities, looseness and the like, and the compactness is good.
Comparative example 10
Comparative example 10 is a comparative example to example 10, cast directly with high chrome iron water without coating strengthening. The composition of the high chromium molten iron, the casting control parameters and the green body heat treatment step used were the same as in step D and step E of example 10.
The working surface is polished to the roughness Ra0.8, no obvious scratch and burn on the surface are caused, and the hardness of the casting finished product is 61.3HRC by using a portable Richter hardness tester.
Compared with the casting of the comparative example 10, the casting of the example 10 reinforced by the material provided by the invention has the hardness improved by 7.7HRC, and the effect is remarkable.
Example 11
This example is an application example of the pre-coating method of the coating material of the present invention, which is used for strengthening the working top coat of the wear-resistant plate standard.
The total amount of the coating material used in this example was 6kg, and the coating material was prepared by ball-milling 3.5kg of 300 mesh Ti powder, 0.75kg of 300 mesh graphite powder, 0.5kg of 300 mesh WC powder, and 1.25kg of 200 mesh mixed metal powder.
Wherein, mixed metal powder component includes: 50wt% of nickel powder, 3wt% of molybdenum powder, 3wt% of rare earth powder, 1.5wt% of magnesium powder, 5wt% of copper powder, 3wt% of cobalt powder and the balance of iron powder.
The preparation method of the coating material comprises the following steps:
s1, weighing nickel powder, molybdenum powder, copper powder, cobalt powder, rare earth powder, magnesium powder and iron powder in proportion, pouring the weighed materials into a ball mill, and grinding and mixing for 15 hours to obtain mixed metal powder with the average particle size of 300 meshes;
s2, weighing titanium powder, graphite powder, tungsten carbide powder and mixed metal powder in proportion, pouring the mixture into a ball mill, and grinding and mixing for 20 hours to obtain the coating material.
The specific steps of using the pre-coating method are as follows:
A. mixing 6kg of powdery coating material, 1.5kg of polyvinyl alcohol aqueous solution with the mass concentration of 1.2wt% and 300g of water, and stirring to form paste, wherein the paste has good formability and is not easy to collapse;
B. manufacturing a wear-resisting plate precoated sand model, and performing mold assembly; adopting a multilayer casting model to cast six wear-resisting plates at one time;
filling the paste on one side of a working surface of a sand mold of the wear-resisting plate, removing redundant paste by using a special scraper or a caliper to ensure that the surface of the paste is smooth and compact, and uniformly pricking a plurality of molten iron overflow holes by using a 5mm iron needle of the Brownia;
according to different design requirements of standard parts of wear-resisting plates, the thickness of the coating is varied from 5mm to 15mm; and recovering the removed excessive paste.
C. Sending the wear-resisting plate sand mold (with multiple layers) coated with the paste into an oven, keeping the temperature at 180 ℃ for 4 to 6 hours, and drying;
D. taking out the dried wear-resistant block sand mold, and pouring high-chromium molten iron;
E. and opening the box, after the casting is cooled to room temperature, removing sand, polishing, and then carrying out high-temperature quenching treatment to obtain the wear-resisting plate casting finished product.
And (3) polishing the casting and infiltration bonding layer until the roughness is Ra0.8, wherein no obvious scratch or burn is formed on the surface, and the hardness of the wear-resisting plate casting finished product is 69HRC (Rockwell hardness) detected by using a portable Richardometer.
The X-ray is adopted to detect the flaw of the casting, so that the inner part of the casting and the strengthening layer have no defects of pinholes, shrinkage cavities, looseness and the like, and the compactness is good.
Comparative example 11
Comparative example 11 is a comparative example to example 11 cast directly with high chrome iron water without coating strengthening. The composition of the high chromium molten iron used, the casting control parameters and the green body heat treatment step were the same as in step D and step E of example 11.
The working surface is polished to the roughness Ra0.8, no obvious scratch and burn are caused on the surface, and the hardness of the obtained casting finished product is 59.5HRC by using a portable Richter hardness tester for detection.
Compared with the casting of the comparative example 11, the casting of the example 11 reinforced by the material of the invention has the hardness improved by 9.5HRC and remarkable effect.
At present, the process disclosed by the invention is applied to some specific industrial fields, and see examples 12-14.
Example 12
The pump cover of the 250JGB slurry pump is used for preparing a pump cover of a slurry pump used in a gold mine area in Shandong, and the working medium of the slurry pump is corrosive flotation pulp.
The pump cover of the original slurry pump is made of common high-chromium cast iron, the abrasion in working is serious, and the service life of the pump cover is about 500 hours generally. In order to extend the operational life of pump caps, attempts have been made to modify the pump caps with a coating material.
In the initial development stage, the adopted coating material comprises the following components in parts by mass: 30 parts of titanium powder, 15 parts of graphite powder, 25 parts of tungsten carbide powder and 50 parts of mixed metal powder; wherein the particle size of the titanium powder is 200 meshes, the particle size of the graphite powder is 200 meshes, the particle size of the tungsten carbide powder is 325 meshes, and the particle size of the mixed metal powder is 200 meshes. Wherein the mixed metal powder consists of 50wt% of nickel powder, 3wt% of molybdenum powder, 5wt% of copper powder, 3wt% of cobalt powder, 3wt% of silicon powder and the balance of iron powder.
And (3) preparing the pump cover of the reinforced slurry pump by using a pre-coating method. The prepared pump cover has poor deoxidation and deslagging effects at a self-propagating combustion interface, excessively low combustion-supporting temperature, insufficient surface combustion or local non-ignition after self-propagating metallurgical bonding, so that a small area of a coating falls off (the thickness of a coating of a medium and large part is more than 20mm, no auxiliary agent reacts and a breakpoint is generated), and the bonding of a composite layer is incomplete.
The improved pump cover and the pump body are assembled and installed, the pump cover and the pump body are used under the original medium condition, perforation occurs after 771 hours, and the flow is insufficient.
In order to further improve the bonding firmness of the self-propagating composite layer, the coating material is further improved, and proper magnesium and rare earth components are introduced into the mixed metal powder, and the specific components are shown in example 1. The improved coating material is adopted to reinforce the working surface of the pump cover, and pump cover pouring experiments show that after metals such as magnesium, rare earth and the like are introduced into the coating material, the continuity condition of combustion reaction of the composite layer is provided, the deoxidation protection effect on a bonding transition area is achieved, and the composite layer is formed completely and reliably.
The pump cover is installed on equipment to operate under the same working condition, and after the pump cover is improved and the use time is 1080 hours, the leakage of the sealing section (non-reinforced coating area) is sealed.
Compared with the working life of 500 hours of a common high-chromium cast iron pump cover, the service life of the pump cover improved by adopting the coating material is prolonged by more than one time, and the working surface of the pump cover is effectively strengthened.
The secondary improved casting is subjected to flaw detection by adopting X rays, the defects of pinholes, shrinkage cavities, looseness and the like do not exist in the casting and the strengthening layer, and the compactness is good.
Taking a high-chromium matrix casting, a primary improved casting (magnesium powder and rare earth powder are not added to a coating) and a secondary improved casting (magnesium powder and rare earth powder are added to a coating), taking a test block according to a standard requirement, and carrying out a wear resistance test, wherein the test blocks are marked as RSA, RSB and RSC in sequence. The test adopts a related method of Procedure A in ASTM G65-2004 (2010) test method for measuring abrasion by using a dry sand/rubber wheel tester, and the abrasion loss of the casting is measured by using the dry sand/rubber wheel tester; and replacing the dry sand/rubber wheel in the test tester with a dry sand/steel wheel, and measuring the abrasion loss of the casting under the steel wheel, wherein the mark is SWAT. The test results are shown in the following table.
BKDR Cr WCIs:
The data can be seen visually, and under a dry sand/rubber wheel test system, the abrasion weight of the secondarily-improved pump cover is reduced by 0.1206g and 14.5mm compared with the abrasion weight of the common high-chromium cast iron pump cover 3 The abrasion weight is reduced by 56.75 percent, and the abrasion volume is reduced by 52.16 percent; under a dry sand/steel wheel test system, the abrasion weight of the secondarily improved pump cover is reduced by 0.101g and 10.2mm compared with that of the common high-chromium cast iron pump cover 3 The abrasion weight is reduced by 32.11 percent and the abrasion volume is reduced by 24.8 percent. Under two different test systems, the abrasion loss of the secondary improved pump cover is obviously superior to that of the common high-chromium cast iron pump cover, and the coating material and the application method can effectively improve the strength and the abrasion resistance of a casting.
As shown in the data, the abrasion loss of the pump cover improved once is obviously reduced compared with that of the common high-chromium cast iron pump cover, and the abrasion resistance of the pump cover improved once is proved to be superior to that of the common high-chromium cast iron pump cover. After magnesium and rare earth components are added, the wear resistance of the secondary improved pump cover is further reduced, the wear resistance of the secondary improved pump cover is further improved, the coating material provided by the invention is proved to have a remarkable enhancing effect on high-chromium iron castings, and the magnesium powder and the rare earth powder in the mixed metal powder are proved to have independent effect in the self-propagating reaction process and are indispensable.
Example 13
The plate hammer is used for preparing quartz stone crushing.
In the prior plate hammer for crushing quartz stones, in order to improve the strength of a hammering face, hard alloy blocks are uniformly cast on the surface of the plate hammer; the cast-in surface is uneven, the stress on the working surface is uneven, and a concentrated falling area exists. After the coating material of the embodiment 2 of the invention is improved and enhanced by a pre-coating process, the surface of the plate hammer is a smooth surface, the surface stress is balanced during hammering, the macro hardness of the relative matrix is improved, and the impact wear resistance is improved.
The two plate hammers are used in Ningxia factories for quartz stone crushing, the Mohs hardness of the quartz stone is 7.3, the crushing amount is 80 tons/hour, and the discharging is 10mm to 50mm.
The existing plate hammer for the cast-in hard alloy block has the phenomenon that the cast-in alloy block falls off in large blocks when the plate hammer is used for 13 days. The plate hammer adopting the process has the advantages that the service time is 30 days, the impact surface is seriously abraded, but no fracture exists, and the coating material can prove that the working surface of the plate hammer is effectively reinforced.
The improved plate hammer is subjected to flaw detection by adopting X rays, the interior of a casting and a strengthening layer have no defects of pinholes, shrinkage cavities, looseness and the like, and the compactness is good.
Taking an improved front plate hammer (matrix high-chromium cast iron, in-cast hard alloy block) and an improved rear plate hammer (matrix high-chromium cast iron after the self-propagating coating process is improved), taking a test block according to standard requirements for carrying out wear resistance test, and sequentially marking as RSD and RSE. The test adopts a related method of Procedure A in ASTM G65-2004 (2010) test method for measuring abrasion by using a dry sand/rubber wheel tester, and the abrasion loss of the casting is measured by using the dry sand/rubber wheel tester; and replacing the dry sand/rubber wheel in the test tester with a dry sand/steel wheel, and measuring the abrasion loss of the casting under the steel wheel, wherein the mark is SWAT. The test results are shown in the following table.
The test results are shown in the following table.
BKDR Cr WCIs:
The data show that the abrasion weight of the improved plate hammer is reduced by 0.0307g and 2.1mm compared with the abrasion weight of the common plate hammer under a dry sand/rubber wheel test system 3 The abrasion weight is reduced by 21.33 percent, and the abrasion volume is reduced by 13.38 percent; under a dry sand/steel wheel test system, the abrasion of the rear plate hammer is improvedThe abrasion loss of the common plate hammer is reduced by 0.0968g and 12.6mm 3 The abrasion weight is reduced by 27.65%, and the abrasion volume is reduced by 26.92%. Under two different test systems, the abrasion loss of the improved plate hammer is obviously superior to that of the common plate hammer, and the coating material and the application method can effectively improve the strength and the abrasion resistance of a casting.
Example 14
The method is used for preparing thin-wall castings such as conveying bent pipes.
Taking a cement slurry conveying elbow of a certain heavy industry enterprise in Hunan as an example, the cement slurry conveying elbow is formed by adopting a film-coated sand mold for pouring, and the existing elbow only coats a coating on the surface of a casting and has no exuviating agent; after improvement, the process is adopted, a precoating method is used for preparing the thin-wall casting, and the thickness of the thin-wall casting is 5mm to 10mm.
The sizes of the two types of bent pipes are controlled by mould modeling, and the wall thicknesses are uniform; and the original powder is mixed with water to prepare a release agent which is coated on the surface of the coated sand core, the forming surface is smoother after cast iron is poured, and the medium has no obvious resistance to flow under the same fluid working condition environment and is not easy to form a fatigue failure area. The X-ray is adopted to detect the flaw of the casting, the defects of pinholes, shrinkage cavities, looseness and the like do not exist in the casting and the strengthening layer, and the compactness is good.
The conveying bent pipe is used for conveying cement slurry, and after 8000 cubic of cement slurry is conveyed by the bent pipe before improvement, the bent pipe is used for washing a through hole and cracks in a failure mode; after the improved elbow is used for conveying 11000 cubic cement slurry, the perforation is failed, and the conveying water yield is increased by 37.5%.
The above description is only a preferred embodiment of the present invention, and all the equivalent changes and modifications made according to the claims of the present invention should be covered by the present invention.
Claims (10)
1. The casting reinforcing coating material is characterized by comprising the following components in parts by mass: 20-70 parts of titanium powder, 3-20 parts of graphite powder, 3-30 parts of tungsten carbide powder and 3-80 parts of mixed metal powder; wherein the particle size of the titanium powder is 200-300 meshes, the particle size of the graphite powder is 200-300 meshes, the particle size of the tungsten carbide powder is 140-325 meshes, and the particle size of the mixed metal powder is 100-200 meshes.
2. The casting reinforcing coating material according to claim 1, characterized by comprising the following components in parts by mass: 30-60 parts of titanium powder, 5-15 parts of graphite powder, 10-25 parts of tungsten carbide powder and 15-50 parts of mixed metal powder; wherein the particle size of the titanium powder is 300 meshes, the particle size of the graphite powder is 300 meshes, the particle size of the tungsten carbide powder is 325 meshes, and the particle size of the mixed metal powder is 100-200 meshes.
3. A casting enhancement coating material according to any one of claims 1 or 2, characterized in that the mixed metal powder comprises the following components in mass percent: 0 to 60wt% of nickel powder, 0 to 10wt% of molybdenum powder, 0 to 10wt% of copper powder, 0 to 60wt% of cobalt powder, 0 to 10wt% of silicon powder, 0 to 10wt% of rare earth powder, 0 to 5wt% of magnesium powder, 0 to 5wt% of boron and the balance of iron powder.
4. The casting enhancement coating material of claim 3, wherein the mixed metal powder comprises the following components in mass percent: 0-60wt% of nickel powder, 0-6wt% of molybdenum powder, 5-10 wt% of copper powder, 2-60 wt% of cobalt powder, 1-3 wt% of silicon powder, 1-3 wt% of rare earth powder, 1-5 wt% of magnesium powder, 0-3wt% of boron and the balance of iron powder.
5. The use of the casting reinforcing coating material as defined in any one of claims 1 to 4, wherein: placing the casting reinforcing coating material in a part to be reinforced in a shell in advance, and pouring the casting reinforcing coating material with high-chromium molten iron after die combination; the casting reinforced coating material is contacted with high-chromium molten iron to generate self-propagating reaction to form a high-strength high-chromium cast-infiltration alloy phase.
6. Use of the cast reinforcement coating material of claim 5, wherein: when the part of the casting to be enhanced is positioned on the surface of the casting, a pre-coating method is adopted; when the part of the casting to be enhanced is positioned in the casting, a precast block method is adopted.
7. Use of the casting-enhancing coating material according to claim 6, characterized in that the pre-coating method comprises in particular the steps of:
A. adding a proper amount of binder and clear water into the powdery coating material, mixing and stirring into paste;
B. directly coating the paste on an area needing to be reinforced on a precoated sand shell/mold core, wherein the coating thickness is 1mm to 30mm;
C. coating a layer of sand-sticking-preventing coating on the area of the precoated sand shell/mold core surface which is not coated with the paste, then heating at low temperature, and drying the paste and the sand-sticking-preventing coating;
D. closing the film-coated sand mold shell, and pouring by using molten high-chromium molten iron to obtain a green body;
E. and (3) after the green body is trimmed, carrying out austenite destabilization heat treatment, cooling, and then carrying out sand blasting, trimming and polishing to obtain the high-strength high-chromium casting.
8. Use of the cast reinforcement coating material of claim 7, wherein: in the step A, the binder is polyvinyl alcohol aqueous solution with the mass concentration of 1.2%, and the mass ratio of the coating material to the binder to the water is 1:1% -2%: 30% -40%.
9. Use of the cast reinforcement coating material according to claim 6, characterized in that the pre-block method comprises in particular the steps of:
A. adding a proper amount of lubricant into the powdery coating material, and mixing and stirring the mixture into viscous powder;
B. filling the viscous powder into a metal mold, forming the viscous powder into a prefabricated block by vibration pressure, and drying the prefabricated block;
C. fixing the prefabricated block at the position of the film-coated sand mold shell to be reinforced, and drying the mold shell;
D. closing the film-coated sand mold shell, and pouring by using molten high-chromium molten iron to obtain a green body;
E. and (3) after the green body is trimmed, carrying out austenite destabilization heat treatment, cooling, and then carrying out sand blasting, trimming and polishing to obtain the high-strength high-chromium casting.
10. Use of a cast reinforcement coating material according to claim 9, characterized in that: in the step A, the lubricant is stearic acid or paraffin, and the feeding mass ratio of the coating material to the lubricant is 1:3% -8%; and in the step B, the pressing pre-pressure is not less than 15 tons.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210939035.6A CN115283607A (en) | 2022-08-05 | 2022-08-05 | Casting reinforcing coating material and application thereof |
| PCT/CA2023/051052 WO2024026576A1 (en) | 2022-08-05 | 2023-08-04 | Composition and process for cast molding objects with titanium carbide coating |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210939035.6A CN115283607A (en) | 2022-08-05 | 2022-08-05 | Casting reinforcing coating material and application thereof |
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| CN102274951B (en) * | 2011-08-04 | 2013-03-06 | 广东新劲刚超硬材料有限公司 | Method for synthesizing titanium carbide-base hard alloy coating on surfaces of castings in situ |
| CN107034460B (en) * | 2017-03-17 | 2019-04-16 | 建平纳鑫粉末冶金有限公司 | A method of preparing titanium carbide base hard alloy coating |
| CN111482579B (en) * | 2020-03-17 | 2022-03-22 | 内蒙古科技大学 | Wear-resistant steel bonded hard alloy composite hammer head and manufacturing method thereof |
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