CN115612896A - Aluminum alloy, application of aluminum alloy and preparation method of railway vehicle gearbox body - Google Patents
Aluminum alloy, application of aluminum alloy and preparation method of railway vehicle gearbox body Download PDFInfo
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- CN115612896A CN115612896A CN202211243718.4A CN202211243718A CN115612896A CN 115612896 A CN115612896 A CN 115612896A CN 202211243718 A CN202211243718 A CN 202211243718A CN 115612896 A CN115612896 A CN 115612896A
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
- C23C18/18—Pretreatment of the material to be coated
- C23C18/1803—Pretreatment of the material to be coated of metallic material surfaces or of a non-specific material surfaces
- C23C18/1824—Pretreatment of the material to be coated of metallic material surfaces or of a non-specific material surfaces by chemical pretreatment
- C23C18/1837—Multistep pretreatment
- C23C18/1841—Multistep pretreatment with use of metal first
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
- C23C18/31—Coating with metals
- C23C18/32—Coating with nickel, cobalt or mixtures thereof with phosphorus or boron
- C23C18/34—Coating with nickel, cobalt or mixtures thereof with phosphorus or boron using reducing agents
- C23C18/36—Coating with nickel, cobalt or mixtures thereof with phosphorus or boron using reducing agents using hypophosphites
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H57/00—General details of gearing
- F16H57/02—Gearboxes; Mounting gearing therein
- F16H57/032—Gearboxes; Mounting gearing therein characterised by the materials used
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T30/00—Transportation of goods or passengers via railways, e.g. energy recovery or reducing air resistance
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- Chemical Kinetics & Catalysis (AREA)
- General Engineering & Computer Science (AREA)
- General Details Of Gearings (AREA)
- Chemically Coating (AREA)
Abstract
The invention belongs to the technical field of railway vehicle gearbox bodies, and particularly relates to an aluminum alloy, application thereof and a preparation method of a railway vehicle gearbox body. The invention provides an aluminum alloy which comprises the following element components in percentage by mass: 0.9 to 1.1% Zn,6.5 to 8% Si,0.6 to 0.8% Fe,3.0 to 3.8% Cu,0.2 to 0.3% Mn,0.2 to 0.35% Mg,0.09 to 0.15% Ti and the balance Al. The aluminum alloy is limited to comprise the components in percentage by mass, so that the fatigue resistance of the aluminum alloy is improved. The aluminum alloy provided by the invention has lower density and higher fatigue resistance, and the railway vehicle gearbox body prepared from the aluminum alloy provided by the invention meets the requirement of light weight and the requirement of fatigue resistance, so that the service life is prolonged.
Description
Technical Field
The invention belongs to the technical field of railway vehicle gearbox bodies, and particularly relates to an aluminum alloy, application thereof and a preparation method of a railway vehicle gearbox body.
Background
The box of traditional urban rail vehicle gear box adopts cast iron material mostly to the rigidity and the intensity of the box that the preparation of cast iron material obtained satisfy service condition requirement, and the stable performance is reliable. However, as the demand for light weight and energy saving increases, attention is being paid to cast aluminum cases. The box body made of cast aluminum can reduce weight by about 64 percent compared with the box body made of cast iron, so that the cast aluminum box body can greatly reduce energy consumption.
However, the strength of cast aluminum boxes is significantly lower than cast iron boxes, especially the fatigue strength, in terms of AlSi 7 Mg 0.3 In the T6 state of the cast aluminum alloy, the average (equivalent) stress of 1000 ten thousand cycle load fatigue strength is only 35MPa, and in the cast iron (QT 400 is taken as an example), the average (equivalent) stress of 1000 ten thousand cycle load fatigue strength can reach more than 130 MPa. In order to meet the requirements of light weight and high strength of the box body of the urban railway vehicle gearbox, the strength of the aluminum alloy needs to be improved while the light weight is ensured.
Disclosure of Invention
In view of the above, the invention provides an aluminum alloy, an application thereof and a preparation method of a rail vehicle gearbox body.
In order to solve the technical problems, the invention provides an aluminum alloy which comprises the following element components in percentage by mass:
preferably, the material comprises the following element components in percentage by mass:
the invention also provides application of the aluminum alloy in the technical scheme in a gearbox body of a railway vehicle.
The invention provides a preparation method of a gearbox body of a railway vehicle, which comprises the following steps:
melting an aluminum source, a zinc source, a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source according to the element ratio to obtain a casting solution;
and injecting the casting solution into a mold for cooling to obtain the gearbox body of the railway vehicle.
Preferably, the melting comprises the steps of:
firstly melting aluminum to obtain aluminum liquid;
mixing the aluminum liquid and zinc for second melting to obtain aluminum-zinc liquid;
and mixing the aluminum zinc liquid with silicon, iron, copper, manganese, magnesium and titanium for third melting to obtain the casting liquid.
Preferably, the temperatures of the first melting and the second melting are 670 to 690 ℃ independently;
the temperature of the third melting is 720-750 ℃.
Preferably, the second melting further comprises: and (4) carrying out exhaust treatment on the system after the second melting.
Preferably, the cooling further comprises:
demolding the cooled system to obtain a cast body;
and sequentially carrying out first zinc dipping, second zinc dipping and nickel plating on the cast body to obtain the gearbox body of the railway vehicle gearbox.
Preferably, the first zinc dipping is to dip the casting body into a first zinc dipping solution;
the second zinc dipping is to dip the first zinc dipped product into a second zinc dipping solution;
the first zinc dipping solution comprises the following components in mass concentration:
the second zinc dipping solution comprises the following components in mass concentration:
preferably, the pH value of the nickel plating solution for nickel plating is 4.2-4.3; the nickel plating solution comprises the following components in mass concentration:
the invention provides an aluminum alloy which comprises the following element components in percentage by mass: 0.9-1.1% Zn, 6.5-8% Si, 0.6-0.8% Fe, 3.0-3.8% Cu, 0.2-0.3% Mn, 0.2-0.35% Mg, 0.09-0.15% Ti and the balance Al. The addition of magnesium and titanium to the aluminum alloy can improve the fatigue resistance and the static strength of the aluminum alloy, and the aluminum alloy provided by the invention has higher fatigue resistance under the combined action of the element components with the mass percentage. The aluminum alloy provided by the invention has lower density and higher fatigue resistance, and the railway vehicle gearbox body prepared from the aluminum alloy provided by the invention meets the requirement of light weight and also meets the requirement of fatigue resistance, so that the service life is prolonged.
Drawings
FIG. 1 is a schematic illustration of an isometric view of a railway vehicle gearbox body prepared in accordance with example 1;
FIG. 2 is a schematic left side view of a railway vehicle gearbox housing prepared in accordance with example 1, wherein 2-1 is an input flange and 2-2 is an output flange;
FIG. 3 is a pictorial representation of a static strength-tensile test;
FIG. 4 is a pictorial representation of a fatigue strength-bending fatigue test;
FIG. 5 is a graph showing fatigue curves of samples of the gearbox housing of the rail vehicle prepared in examples 1 to 3.
Detailed Description
The invention provides an aluminum alloy which comprises the following element components in percentage by mass:
the aluminum alloy of the present invention comprises 0.9 to 1.1% by mass of Zn, preferably 0.93 to 1.08%.
The aluminum alloy of the present invention comprises, in mass%, 6.5 to 8% by weight of Si, preferably 6.6 to 7%. According to the invention, the silicon can increase the fluidity of the melt and reduce the risk of cracking of the gearbox body of the rail vehicle.
The aluminum alloy of the present invention includes 0.6 to 0.8% by mass of Fe, preferably 0.64 to 0.66%. In the invention, the addition of the iron in the above dosage range in the aluminum alloy can prevent the sticking film and facilitate the demoulding and forming.
The aluminum alloy of the present invention comprises 3.0 to 3.8% by mass of Cu, preferably 3.03 to 3.1%. In the present invention, the above amount of copper is favorable for casting and molding and also favorable for nickel plating.
The aluminum alloy of the present invention comprises 0.2 to 0.3% by mass of Mn, preferably 0.21 to 0.23%. In the invention, the manganese in the dosage range is beneficial to refining the recrystallized grains, so that the pores of the casting body are uniform, and the formation of shrinkage porosity of the aluminum alloy is reduced.
The aluminum alloy of the present invention comprises, in mass%, 0.2 to 0.35% by weight of Mg, preferably 0.28 to 0.3%. In the present invention, the magnesium can improve the strength of the aluminum alloy.
The aluminum alloy of the present invention comprises, in mass%, 0.09 to 0.15% by mass of Ti, preferably 0.1 to 0.12%. In the invention, the titanium can refine the grain structure of the cast aluminum alloy and improve the fatigue resistance and the static strength of the aluminum alloy.
The aluminum alloy provided by the invention comprises the balance of Al in percentage by mass.
The aluminum alloy provided by the invention has lower density and higher mechanical strength, and the density of the aluminum alloy is 2.67/m 3 ～2.69t/m 3 The yield strength of the aluminum alloy is 219-237 MPa, the tensile strength of the aluminum alloy is 245-297 MPa, and the Brinell hardness of the aluminum alloy is 79-82. Although metal elements with high density such as Mn, ti, fe and the like are added in the aluminum alloy provided by the invention, the box body has air holes after casting, so that the density of the prepared aluminum alloy is lower and lower than that of pure aluminum.
In the present invention, the method for producing the aluminum alloy preferably includes the steps of:
and melting an aluminum source, a zinc source, a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source according to the element ratio, and then casting to obtain the aluminum alloy.
In the present invention, if there is no particular requirement for the aluminum source, the zinc source, the silicon source, the iron source, the copper source, the manganese source, the magnesium source, and the titanium source, commercially available products conventionally used in the art may be used.
In the present invention, the melting preferably comprises the steps of:
fourthly, melting an aluminum source to obtain aluminum liquid;
mixing the aluminum liquid and a zinc source, and performing fifth melting to obtain aluminum-zinc liquid;
and mixing the aluminum-zinc liquid with a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source, and carrying out sixth melting to obtain a casting liquid.
In the invention, an aluminum source is melted for the fourth time to obtain aluminum liquid. In the present invention, the purity of the aluminum source is preferably 99.7% or more, and more preferably 99.8 to 99.9%. In the present invention, the temperature of the fourth melting is preferably 670 to 690 ℃, more preferably 675 to 685 ℃. In the present invention, the time for the fourth melting is not particularly limited as long as the melting is completed.
In the present invention, it is preferable that the fourth melt further comprises: and deslagging the fourth melted system to obtain the aluminum liquid. In the present invention, the deslagging is preferably performed by removing dross on the surface of the filtrate by using a metal paddle.
The invention preferably uses a spectrum analyzer to measure the chemical components in the aluminum liquid.
After the aluminum liquid is obtained, the aluminum liquid and a zinc source are mixed and subjected to fifth melting to obtain the aluminum-zinc liquid. In the present invention, the temperature of the fifth melting is preferably 670 to 690 ℃, more preferably 675 to 685 ℃. In the present invention, there is no particular requirement for the time of the fifth melting as long as the melting is completed.
In the present invention, it is preferable that the fifth melting further comprises: and carrying out exhaust treatment on the system after the fifth melting to obtain the aluminum zinc liquid. In the invention, the exhaust treatment is preferably to stir the aluminum zinc liquid by using a nitrogen nozzle so as to fully discharge bubbles.
After the aluminum-zinc liquid is obtained, the aluminum-zinc liquid, a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source are mixed and subjected to sixth melting to obtain a casting liquid. In the present invention, the temperature of the sixth melting is preferably 720 to 750 ℃, and more preferably 730 to 740 ℃. In the present invention, the time for the sixth melting is not particularly limited as long as the melting is completed.
In the present invention, it is preferable that the sixth melting further comprises: and (4) cooling the sixth melted system, and detecting the content of each metal element in the sixth melted system by using an optical spectrum analyzer. In the present invention, the temperature after the temperature reduction is preferably 670 to 690 ℃, more preferably 675 to 685 ℃. In the present invention, the temperature reduction is preferably natural temperature reduction. The invention uses a spectrum analyzer to detect the content of each metal element in the sixth molten system so as to ensure that each metal element meets the composition proportion of the aluminum alloy.
The invention has no special requirements on the casting and can adopt a conventional mode in the field.
The invention also provides application of the aluminum alloy in the technical scheme in a gearbox body of a railway vehicle. The railway vehicle gearbox body prepared from the aluminum alloy provided by the invention has the performances of light weight and high strength.
The invention also provides a preparation method of the railway vehicle gearbox body, which comprises the following steps:
melting an aluminum source, a zinc source, a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source according to the element ratio to obtain a casting solution;
and injecting the casting solution into a mold for cooling to obtain the gearbox body of the railway vehicle.
In the present invention, if there is no particular description on the sources of the aluminum source, the zinc source, the silicon source, the iron source, the copper source, the manganese source, the magnesium source, and the titanium source, commercially available products conventionally used in the art may be used.
According to the invention, an aluminum source, a zinc source, a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source are melted according to the element proportion to obtain a casting solution. In the present invention, the melting preferably comprises the steps of:
firstly melting an aluminum source to obtain aluminum liquid;
mixing the aluminum liquid and a zinc source for second melting to obtain aluminum-zinc liquid;
and mixing the aluminum-zinc liquid with a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source, and performing third melting to obtain the casting liquid.
According to the invention, an aluminum source is firstly melted to obtain aluminum liquid. In the present invention, the purity of the aluminum source is preferably 99.7% or more, and more preferably 99.8 to 99.9%. In the present invention, the temperature of the first melting is preferably 670 to 690 ℃, more preferably 675 to 685 ℃. In the present invention, the time for the first melting is not particularly limited as long as the melting can be completed.
In the present invention, it is preferable that the first melting further comprises: and deslagging the system after the first melting to obtain the aluminum liquid. In the present invention, the deslagging is preferably performed by removing dross from the surface using a metal paddle.
After deslagging, the invention preferably uses a spectrometer to measure the chemical components in the aluminum liquid.
After the aluminum liquid is obtained, the aluminum liquid and a zinc source are mixed and subjected to second melting to obtain the aluminum-zinc liquid. In the present invention, the temperature of the second melting is preferably 670 to 690 ℃, more preferably 675 to 685 ℃. In the present invention, the time for the second melting is not particularly limited as long as the melting is completed.
In the present invention, it is preferable that the second melting further comprises: and carrying out exhaust treatment on the system after the second melting to obtain the aluminum zinc liquid. In the present invention, the exhaust treatment is preferably performed by stirring the second molten product using a nitrogen gas nozzle so that bubbles are sufficiently discharged. In the invention, the exhaust treatment can remove bubbles in the aluminum-zinc liquid, thereby preventing the subsequent coating from cracking after microscopic bubbles appear to cause uneven coating.
After the aluminum-zinc liquid is obtained, the aluminum-zinc liquid, a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source are mixed and subjected to third melting to obtain the casting liquid. In the present invention, the temperature of the third melting is preferably 720 to 750 ℃, more preferably 730 to 740 ℃. In the present invention, the time for the third melting is not particularly limited as long as the melting is completed.
In the present invention, it is preferable that the third melting further comprises: and cooling the third melted system, and detecting the content of each metal element in the third melted system by using a spectrum analyzer. In the present invention, the temperature after the temperature reduction is preferably 670 to 690 ℃, more preferably 675 to 685 ℃. In the present invention, the temperature reduction is preferably natural temperature reduction. The invention uses a spectrum analyzer to detect the content of each metal element in the third melted system so as to ensure that each metal element meets the composition proportion of the aluminum alloy.
After the casting solution is obtained, the casting solution is injected into a mold to be cooled, and the gearbox body of the railway vehicle gearbox is obtained. In the invention, the mold is preferably a metal mold, and the metal mold is a mold of a gearbox body of a railway vehicle. The present invention preferably utilizes a metal mold low pressure casting process to cast a rail vehicle gearbox housing.
In the present invention, the temperature after cooling is preferably normal temperature, and in the present invention, the temperature of normal temperature is preferably 20 to 35 ℃, and more preferably 25 to 30 ℃. The cooling method of the present invention is not particularly limited as long as the desired temperature can be achieved.
The vehicle gearbox body with a complex structure is prepared by directly injecting the molten liquid into the die. The aluminum alloy provided by the invention has higher fatigue resistance and can adapt to the working condition of uneven change of the section of the gearbox body of the road vehicle.
In the present invention, after the cooling, it is preferable that:
demolding the cooled system to obtain a cast body;
and sequentially carrying out first zinc dipping, second zinc dipping and nickel plating on the cast body to obtain the gearbox body of the railway vehicle gearbox.
The invention has no special requirements on the demolding and can be realized by adopting a conventional mode in the field.
In the present invention, the first zincating is preferably performed by immersing the cast body in a first zincating solution. In the present invention, the first zincating solution preferably comprises the following components in mass concentration:
in the invention, the mass concentration of the sodium hydroxide in the first zinc dipping solution is preferably 480-520 g/L, and more preferably 500g/L; the mass concentration of the zinc oxide in the first zinc dipping solution is preferably 145-155 g/L, and more preferably 150g/L; the mass concentration of the potassium sodium tartrate in the first zinc dipping solution is preferably 13-18 g/L, and more preferably 15g/L; the mass concentration of ferric trichloride in the first zinc-dipping solution is preferably 1.2-2.5 g/L, and more preferably 2g/L.
In the invention, the temperature of the first zinc dipping is preferably 20-30 ℃, and more preferably 25 ℃; the time for the first zincate is preferably 50 to 70s, more preferably 60s.
In the present invention, it is preferable that the first zinc dipping further comprises: drying the first zinc-dipped product and then obtaining zinc by first zinc dippingThe layer is removed. In the present invention, the drying is preferably blow drying. In the present invention, the method for removing the zinc layer is preferably to uniformly spray an aqueous sodium nitrate solution having a mass concentration of 50% onto the surface of the dried product. In the present invention, the spraying amount of the sodium nitrate aqueous solution is preferably 4 to 6mL/cm 2 More preferably 4.5 to 5mL/cm 2 (ii) a The residence time of the sodium nitrate aqueous solution on the surface of the product after drying is preferably not less than 5min, more preferably 6 to 10min. In the present invention, the temperature of the spraying is preferably 23 to 27 ℃, and more preferably 25 ℃; the relative humidity of the spray environment is preferably 65% or less, more preferably 55 to 60%.
In the present invention, the second zincating is preferably performed by immersing the ingot in a second zincating solution. In the present invention, the second zincating solution preferably comprises the following components in mass concentration:
in the invention, the mass concentration of the sodium hydroxide in the second zinc dipping solution is preferably 145-155 g/L, and more preferably 150g/L; the mass concentration of zinc oxide in the second zinc dipping solution is preferably 45-55 g/L, and more preferably 50g/L; the mass concentration of the potassium sodium tartrate in the second zinc dipping solution is preferably 25-35 g/L, and more preferably 30g/L; the mass concentration of ferric trichloride in the second zinc dipping solution is preferably 1.5-2.5 g/L, and more preferably 2g/L.
In the invention, the temperature of the second zinc dipping is preferably 20-30 ℃, and more preferably 25 ℃; the time for the second zincate is preferably 25 to 35s, more preferably 30s.
In the present invention, it is preferable that the second zinc dipping further comprises: and drying the second zinc-dipped product. In the present invention, the drying is preferably blow drying.
According to the invention, the zinc layer obtained by the replacement reaction can be dissolved by the first zinc dipping, but the zinc layer obtained by the first zinc dipping is rough and porous and has poor adhesive force; meanwhile, a small amount of oxide film is remained on the surface of the casting body after the first zinc dipping. According to the invention, after the core layer obtained by the first zinc dipping is removed, the thin, uniform and fine zinc layer with strong binding force can be obtained by the second zinc dipping, so that the nickel plating effect is improved.
In the present invention, the nickel plating solution for nickel plating preferably includes the following components in mass concentration:
in the invention, the mass concentration of the nickel sulfate in the nickel plating solution is preferably 30-40 g/L, and more preferably 35g/L; the mass concentration of sodium acetate in the nickel plating solution is preferably 30-40 g/L, and more preferably 35g/L; the mass concentration of sodium sulfite in the nickel plating solution is preferably 10-20 g/L, and more preferably 15g/L; the mass concentration of the sodium citrate in the nickel plating solution is preferably 10-15 g/L, and more preferably 12g/L. In the invention, the pH value of the nickel plating solution is preferably 4.2-4.3; the temperature of the nickel plating solution is preferably 80 to 90 ℃, and more preferably 85 ℃. In the present invention, the time for the nickel plating is preferably 50 to 70 seconds, and more preferably 60 seconds.
In the present invention, the nickel-plated steel further preferably includes: and drying the nickel-plated product. In the present invention, the drying is preferably blow drying.
According to the invention, the surface strength of the gearbox body of the railway vehicle can be improved by performing the first zinc dipping, the second zinc dipping and the nickel plating on the surface of the casting body. In order to save cost, the invention preferably only carries out the first zinc dipping, the second zinc dipping and the nickel plating on the input end flange surface and the output end flange surface in the gearbox box body of the railway vehicle so as to meet the requirement of the gearbox box body of the railway vehicle on strength and prolong the service life of the gearbox box body of the railway vehicle.
The mechanical property of the aluminum alloy is improved from two aspects of the composition proportion of the aluminum alloy material and the mechanical processing surface treatment, so that the mechanical property of the gearbox body of the railway vehicle gearbox is improved, and the safety allowance under the condition of abnormal vibration of the railway vehicle is ensured.
In order to further illustrate the present invention, the following embodiments are described in detail, but they should not be construed as limiting the scope of the present invention.
Example 1
460kg of aluminum is melted at 680 ℃ and then surface scum is removed by a metal plectrum to obtain aluminum liquid; mixing the aluminum liquid and 4.88kg of zinc, melting at 680 ℃, and stirring and exhausting by using a nitrogen spray pipe to obtain aluminum-zinc liquid; mixing aluminum zinc solution with 34.5kg of silicon, 3.35kg of iron, 16.0kg of copper, 1.10kg of manganese, 1.48kg of magnesium and 0.5kg of titanium, and melting at 735 ℃ to obtain casting solution; naturally cooling the casting solution to 680 ℃, and detecting the content of each metal element by using a spectrum analyzer;
injecting the casting solution into a metal mold of a gearbox body of the railway vehicle, performing metal mold low-pressure casting, cooling to 25 ℃, and demolding to obtain a cast body;
sequentially carrying out first zinc dipping, removing a zinc layer obtained by the first zinc dipping, second zinc dipping and nickel plating on an input end flange and an output end flange in the casting body to obtain a gearbox body of the railway vehicle; wherein the first zinc dipping is to dip the casting body in a first zinc dipping solution with the temperature of 25 ℃ for 60s; the mass concentration of sodium hydroxide in the first zinc dipping solution is 500g/L, the mass concentration of zinc oxide is 150g/L, the mass concentration of potassium sodium tartrate is 15g/L, and the mass concentration of ferric trichloride is 2g/L; according to 4.59mL/cm 2 Spraying 50mL of 50 mass percent sodium nitrate aqueous solution on the surface of the first zinc-dipped product, and soaking the casting body without the zinc layer in a second zinc dipping solution at the temperature of 25 ℃ for 30s after 10 min; the mass concentration of sodium hydroxide in the second zinc dipping solution is 150g/L, the mass concentration of zinc oxide is 50g/L, the mass concentration of potassium sodium tartrate is 30g/L, and the mass concentration of ferric trichloride is 2g/L; drying the second zinc-dipped product, and then plating nickel on the surfaces of the input end flange and the output end flange for 60s, wherein the temperature of a nickel plating solution for nickel plating is 85 ℃, and the pH value is 4.2; the mass concentration of nickel sulfate in the nickel plating solution is 35g/L, the mass concentration of sodium acetate is 15g/L, the mass concentration of sodium sulfite is 20g/L, and the mass concentration of sodium citrate is 12g/L.
Example 2
460kg of aluminum is melted at 680 ℃ and then surface scum is removed by a metal plectrum to obtain aluminum liquid; mixing the aluminum liquid and 4.9kg of zinc, melting at 680 ℃, and stirring and exhausting by using a nitrogen spray pipe to obtain aluminum-zinc liquid; mixing aluminum zinc solution with 35kg of silicon, 3.42kg of iron, 16.1kg of copper, 1.1kg of manganese, 1.5kg of magnesium and 0.6kg of titanium, and melting at 735 ℃ to obtain casting solution; naturally cooling the casting solution to 680 ℃, and detecting the content of each metal element by using a spectrum analyzer;
injecting the casting solution into a metal mold of a gearbox body of the railway vehicle, performing metal mold low-pressure casting, cooling to 25 ℃, and demolding to obtain a cast body;
sequentially carrying out first zinc dipping, removing a zinc layer obtained by the first zinc dipping, second zinc dipping and nickel plating on an input end flange and an output end flange in the casting body to obtain a gearbox body of the railway vehicle; wherein the first zinc dipping is to dip the casting body in a first zinc dipping solution with the temperature of 25 ℃ for 60s; the mass concentration of sodium hydroxide in the first zinc dipping solution is 500g/L, the mass concentration of zinc oxide is 150g/L, the mass concentration of potassium sodium tartrate is 15g/L, and the mass concentration of ferric trichloride is 2g/L; spraying 50mL of 50% sodium nitrate aqueous solution on the surface of the first zinc-dipped product, and soaking the casting body without the zinc layer in a second zinc dipping solution at the temperature of 25 ℃ for 30s after 10 min; the mass concentration of sodium hydroxide in the second zinc dipping solution is 150g/L, the mass concentration of zinc oxide is 50g/L, the mass concentration of potassium sodium tartrate is 30g/L, and the mass concentration of ferric trichloride is 2g/L; drying the second zinc-dipped product, and then plating nickel on the surfaces of the input end flange and the output end flange for 60s, wherein the temperature of a nickel plating solution for nickel plating is 85 ℃, and the pH value is 4.2; the mass concentration of nickel sulfate in the nickel plating solution is 35g/L, the mass concentration of sodium acetate is 15g/L, the mass concentration of sodium sulfite is 20g/L, and the mass concentration of sodium citrate is 12g/L.
Example 3
460Kg of aluminum is melted at 680 ℃ and then the scum on the surface is removed by a metal plectrum to obtain aluminum liquid; mixing the aluminum liquid and 4.85kg of zinc, melting at 680 ℃, and stirring and exhausting by using a nitrogen spray pipe to obtain aluminum-zinc liquid; mixing aluminum zinc solution with 34kg of silicon, 3.36kg of iron, 15.8kg of copper, 1.05kg of manganese, 1.48kg of magnesium and 0.6kg of titanium, and melting at 735 ℃ to obtain casting solution; naturally cooling the casting solution to 680 ℃, and detecting the content of each metal element by using a spectrum analyzer;
injecting the casting solution into a metal mold of a gearbox body of the railway vehicle, performing metal mold low-pressure casting, cooling to 25 ℃, and demolding to obtain a cast body;
sequentially carrying out first zinc dipping, removing a zinc layer obtained by the first zinc dipping, second zinc dipping and nickel plating on an input end flange and an output end flange in the casting body to obtain a gearbox body of the railway vehicle; wherein the first zinc dipping is to dip the casting body in a first zinc dipping solution with the temperature of 25 ℃ for 60s; the mass concentration of sodium hydroxide in the first zinc dipping solution is 500g/L, the mass concentration of zinc oxide is 150g/L, the mass concentration of potassium sodium tartrate is 15g/L, and the mass concentration of ferric trichloride is 2g/L; spraying 50mL of 50 mass percent sodium nitrate aqueous solution on the surface of the first zinc-dipped product, and soaking the casting body without the zinc layer in a second zinc dipping solution at the temperature of 25 ℃ for 30s after 10 min; the mass concentration of sodium hydroxide in the second zinc dipping solution is 150g/L, the mass concentration of zinc oxide is 50g/L, the mass concentration of potassium sodium tartrate is 30g/L, and the mass concentration of ferric trichloride is 2g/L; drying the second zinc-dipped product, and then plating nickel on the surfaces of the input end flange and the output end flange for 60s, wherein the temperature of a nickel plating solution for nickel plating is 85 ℃, and the pH value is 4.2; the mass concentration of nickel sulfate in the nickel plating solution is 35g/L, the mass concentration of sodium acetate is 15g/L, the mass concentration of sodium sulfite is 20g/L, and the mass concentration of sodium citrate is 12g/L.
Example 1 a schematic representation of an isometric view of a railway vehicle gearbox body prepared is shown in figure 1; example 1 a schematic representation of a left side view of a railway vehicle gearbox housing prepared is shown in figure 2, where 2-1 is the input end flange and 2-2 is the output end flange.
The yield strength, tensile strength and brinell hardness of the rail vehicle gearbox casings prepared in examples 1-3 were tested after sectioning the sample blocks at the same position (position indicated by red rectangle in fig. 2) on the three gearbox casings prepared in examples 1-3 according to EN 1999-1-3-2007 european norm 9: aluminum structural design-parts 1-3: fatigue-prone structure, the results of which are listed in table 1. In the table, rp0.2 is yield strength, rm is tensile strength, and HBS hardness is distributed hardness. The physical diagram of the static strength-tensile test is shown in fig. 3. Fig. 4 shows a physical diagram of the fatigue strength-bending fatigue test.
Table 1 mechanical properties of three gear housings prepared in examples 1 to 3
The rail vehicle gearbox body prepared in the embodiment 1-3 is subjected to an anti-fatigue test according to a cast aluminum alloy fatigue strength evaluation standard ANALYTICAL STRENGTH ASSESSMENT-FKM2012, specifically, a rail vehicle gearbox body sample prepared in the embodiment 1-3 is subjected to 7000 ten thousand bending tests on the test equipment in fig. 4, the stress of the sample is measured in real time, a data acquisition system acquires and counts data, and an S-N curve is automatically generated, as shown in fig. 5.
As can be seen by combining the table 1 and the figure 5, the railway vehicle gearbox body provided by the invention has lower density and higher mechanical property.
Under the condition of not changing the structural design and the raw material cost of the gearbox body of the railway vehicle, the strength allowance of the gearbox body is improved to the maximum extent, and the average equivalent stress corresponding to 1000 ten thousand fatigue cycle loads is improved from 35MPa to 41MPa; the safety strength of the nickel plating surface is higher, and the HBS hardness (Brinell hardness) is improved from 75 to more than 80; the gearbox body of the railway vehicle gearbox meets the requirement of worse use working conditions, and is low in cost and convenient to popularize. The equivalent stress is calculated according to a Miner linear fatigue accumulated damage rule and a material fatigue curve (S-N curve).
Although the present invention has been described in detail with reference to the above embodiments, it is only a part of the embodiments of the present invention, not all of the embodiments, and other embodiments can be obtained without inventive step according to the embodiments, and the embodiments are within the scope of the present invention.
Claims (10)
1. An aluminum alloy comprises the following element components in percentage by mass:
2. the aluminum alloy of claim 1, comprising the following elemental compositions in percent by mass:
3. use of the aluminium alloy of claim 1 or 2 in a gearbox housing for a rail vehicle.
4. A preparation method of a railway vehicle gearbox body comprises the following steps:
melting an aluminum source, a zinc source, a silicon source, an iron source, a copper source, a manganese source, a magnesium source and a titanium source according to the element ratio to obtain a casting solution;
and injecting the casting solution into a mold for cooling to obtain the gearbox body of the railway vehicle.
5. The method of claim 4, wherein the melting comprises the steps of:
firstly melting aluminum to obtain aluminum liquid;
mixing the aluminum liquid and zinc for second melting to obtain aluminum-zinc liquid;
and mixing the aluminum-zinc liquid with silicon, iron, copper, manganese, magnesium and titanium for third melting to obtain the casting liquid.
6. The method of claim 5, wherein the first melt and the second melt are independently at a temperature of 670 to 690 ℃;
the temperature of the third melting is 720-750 ℃.
7. The method according to claim 5 or 6, further comprising, after the second melting: and (4) carrying out exhaust treatment on the system after the second melting.
8. The method of claim 4, further comprising, after said cooling:
demolding the cooled system to obtain a cast body;
and sequentially carrying out first zinc dipping, second zinc dipping and nickel plating on the cast body to obtain the gearbox body of the railway vehicle gearbox.
9. The method according to claim 8, wherein the first zincating is immersing the cast body in a first zincating solution;
the second zinc dipping is to dip the first zinc dipped product into a second zinc dipping solution;
the first zinc dipping solution comprises the following components in mass concentration:
the second zinc dipping solution comprises the following components in mass concentration:
10. the method according to claim 8, wherein the pH of the nickel plating solution is 4.2 to 4.3; the nickel plating solution comprises the following components in mass concentration:
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