CN117144231A - 一种高韧性耐蚀合金石墨钢轧辊的制备方法 - Google Patents
一种高韧性耐蚀合金石墨钢轧辊的制备方法 Download PDFInfo
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- CN117144231A CN117144231A CN202311423336.4A CN202311423336A CN117144231A CN 117144231 A CN117144231 A CN 117144231A CN 202311423336 A CN202311423336 A CN 202311423336A CN 117144231 A CN117144231 A CN 117144231A
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 77
- 239000010959 steel Substances 0.000 title claims abstract description 77
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims abstract description 66
- 229910002804 graphite Inorganic materials 0.000 title claims abstract description 38
- 239000010439 graphite Substances 0.000 title claims abstract description 38
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 35
- 239000000956 alloy Substances 0.000 title claims abstract description 35
- 238000005260 corrosion Methods 0.000 title claims abstract description 31
- 230000007797 corrosion Effects 0.000 title claims abstract description 31
- 238000002360 preparation method Methods 0.000 title claims abstract description 11
- 238000010438 heat treatment Methods 0.000 claims abstract description 50
- 239000004964 aerogel Substances 0.000 claims abstract description 44
- HZEWFHLRYVTOIW-UHFFFAOYSA-N [Ti].[Ni] Chemical compound [Ti].[Ni] HZEWFHLRYVTOIW-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000000203 mixture Substances 0.000 claims abstract description 20
- 238000000034 method Methods 0.000 claims abstract description 13
- 229910021389 graphene Inorganic materials 0.000 claims abstract description 9
- VYLVYHXQOHJDJL-UHFFFAOYSA-K cerium trichloride Chemical compound Cl[Ce](Cl)Cl VYLVYHXQOHJDJL-UHFFFAOYSA-K 0.000 claims abstract description 7
- ICAKDTKJOYSXGC-UHFFFAOYSA-K lanthanum(iii) chloride Chemical compound Cl[La](Cl)Cl ICAKDTKJOYSXGC-UHFFFAOYSA-K 0.000 claims abstract description 7
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 61
- 239000000243 solution Substances 0.000 claims description 61
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 51
- 238000007747 plating Methods 0.000 claims description 47
- 230000001680 brushing effect Effects 0.000 claims description 43
- 239000007788 liquid Substances 0.000 claims description 39
- 239000012153 distilled water Substances 0.000 claims description 35
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 30
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 30
- 238000002156 mixing Methods 0.000 claims description 27
- 238000001816 cooling Methods 0.000 claims description 26
- 238000004140 cleaning Methods 0.000 claims description 23
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 22
- 230000004913 activation Effects 0.000 claims description 22
- 239000011240 wet gel Substances 0.000 claims description 22
- 238000003723 Smelting Methods 0.000 claims description 21
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 21
- 150000002910 rare earth metals Chemical class 0.000 claims description 21
- 244000137852 Petrea volubilis Species 0.000 claims description 20
- 238000005266 casting Methods 0.000 claims description 16
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 15
- 229910000519 Ferrosilicon Inorganic materials 0.000 claims description 15
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 claims description 15
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 15
- 239000011575 calcium Substances 0.000 claims description 15
- 229910052791 calcium Inorganic materials 0.000 claims description 15
- 239000008367 deionised water Substances 0.000 claims description 15
- 229910021641 deionized water Inorganic materials 0.000 claims description 15
- 238000007599 discharging Methods 0.000 claims description 15
- 235000019441 ethanol Nutrition 0.000 claims description 15
- 229910052742 iron Inorganic materials 0.000 claims description 15
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 15
- 229910052710 silicon Inorganic materials 0.000 claims description 15
- 239000010703 silicon Substances 0.000 claims description 15
- 238000005406 washing Methods 0.000 claims description 15
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 13
- 229910052799 carbon Inorganic materials 0.000 claims description 13
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 12
- 239000011777 magnesium Substances 0.000 claims description 12
- 229910052749 magnesium Inorganic materials 0.000 claims description 12
- 229910052684 Cerium Inorganic materials 0.000 claims description 11
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 11
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims description 11
- 239000007789 gas Substances 0.000 claims description 11
- 229910052746 lanthanum Inorganic materials 0.000 claims description 11
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 claims description 11
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 11
- 239000011780 sodium chloride Substances 0.000 claims description 11
- 229910052717 sulfur Inorganic materials 0.000 claims description 11
- 239000011593 sulfur Substances 0.000 claims description 11
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 10
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 10
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 10
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 10
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 10
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 10
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 10
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 10
- 229910052788 barium Inorganic materials 0.000 claims description 10
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 claims description 10
- 229910052804 chromium Inorganic materials 0.000 claims description 10
- 239000011651 chromium Substances 0.000 claims description 10
- 238000001035 drying Methods 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 229910052750 molybdenum Inorganic materials 0.000 claims description 10
- 239000011733 molybdenum Substances 0.000 claims description 10
- 229910052698 phosphorus Inorganic materials 0.000 claims description 10
- 239000011574 phosphorus Substances 0.000 claims description 10
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical compound OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 claims description 10
- 239000012266 salt solution Substances 0.000 claims description 10
- 239000007787 solid Substances 0.000 claims description 10
- 239000000126 substance Substances 0.000 claims description 10
- 239000000725 suspension Substances 0.000 claims description 10
- 150000003608 titanium Chemical class 0.000 claims description 10
- 230000003213 activating effect Effects 0.000 claims description 8
- 239000007921 spray Substances 0.000 claims description 8
- 238000003756 stirring Methods 0.000 claims description 8
- 229910000600 Ba alloy Inorganic materials 0.000 claims description 7
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 239000011521 glass Substances 0.000 claims description 7
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 7
- 239000002893 slag Substances 0.000 claims description 7
- 239000010936 titanium Substances 0.000 claims description 7
- 229910052719 titanium Inorganic materials 0.000 claims description 7
- 229910000604 Ferrochrome Inorganic materials 0.000 claims description 6
- 229910001309 Ferromolybdenum Inorganic materials 0.000 claims description 6
- 229910000863 Ferronickel Inorganic materials 0.000 claims description 6
- 229910001200 Ferrotitanium Inorganic materials 0.000 claims description 6
- 229910001145 Ferrotungsten Inorganic materials 0.000 claims description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 6
- 239000012300 argon atmosphere Substances 0.000 claims description 6
- 239000000835 fiber Substances 0.000 claims description 6
- 238000004528 spin coating Methods 0.000 claims description 6
- 238000009210 therapy by ultrasound Methods 0.000 claims description 6
- -1 10g/L of 2 Chemical compound 0.000 claims description 5
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 5
- DKGAVHZHDRPRBM-UHFFFAOYSA-N Tert-Butanol Chemical compound CC(C)(C)O DKGAVHZHDRPRBM-UHFFFAOYSA-N 0.000 claims description 5
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 5
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 claims description 5
- 229910052921 ammonium sulfate Inorganic materials 0.000 claims description 5
- 235000011130 ammonium sulphate Nutrition 0.000 claims description 5
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 5
- 239000004327 boric acid Substances 0.000 claims description 5
- 229910052796 boron Inorganic materials 0.000 claims description 5
- NTQGILPNLZZOJH-UHFFFAOYSA-N disilicon Chemical compound [Si]#[Si] NTQGILPNLZZOJH-UHFFFAOYSA-N 0.000 claims description 5
- 238000004108 freeze drying Methods 0.000 claims description 5
- 238000007710 freezing Methods 0.000 claims description 5
- 230000008014 freezing Effects 0.000 claims description 5
- LAIZPRYFQUWUBN-UHFFFAOYSA-L nickel chloride hexahydrate Chemical compound O.O.O.O.O.O.[Cl-].[Cl-].[Ni+2] LAIZPRYFQUWUBN-UHFFFAOYSA-L 0.000 claims description 5
- RRIWRJBSCGCBID-UHFFFAOYSA-L nickel sulfate hexahydrate Chemical compound O.O.O.O.O.O.[Ni+2].[O-]S([O-])(=O)=O RRIWRJBSCGCBID-UHFFFAOYSA-L 0.000 claims description 5
- 229940116202 nickel sulfate hexahydrate Drugs 0.000 claims description 5
- 229910052757 nitrogen Inorganic materials 0.000 claims description 5
- 239000003921 oil Substances 0.000 claims description 5
- DCKVFVYPWDKYDN-UHFFFAOYSA-L oxygen(2-);titanium(4+);sulfate Chemical compound [O-2].[Ti+4].[O-]S([O-])(=O)=O DCKVFVYPWDKYDN-UHFFFAOYSA-L 0.000 claims description 5
- 238000005498 polishing Methods 0.000 claims description 5
- HNJBEVLQSNELDL-UHFFFAOYSA-N pyrrolidin-2-one Chemical compound O=C1CCCN1 HNJBEVLQSNELDL-UHFFFAOYSA-N 0.000 claims description 5
- 229910052702 rhenium Inorganic materials 0.000 claims description 5
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 claims description 5
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 5
- NLJMYIDDQXHKNR-UHFFFAOYSA-K sodium citrate Chemical compound O.O.[Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O NLJMYIDDQXHKNR-UHFFFAOYSA-K 0.000 claims description 5
- 239000001488 sodium phosphate Substances 0.000 claims description 5
- 229910000162 sodium phosphate Inorganic materials 0.000 claims description 5
- 238000000967 suction filtration Methods 0.000 claims description 5
- 229910000348 titanium sulfate Inorganic materials 0.000 claims description 5
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 claims description 5
- FQNGWRSKYZLJDK-UHFFFAOYSA-N [Ca].[Ba] Chemical compound [Ca].[Ba] FQNGWRSKYZLJDK-UHFFFAOYSA-N 0.000 claims description 3
- 229910000640 Fe alloy Inorganic materials 0.000 abstract description 5
- 230000000536 complexating effect Effects 0.000 abstract description 2
- 230000006911 nucleation Effects 0.000 abstract 1
- 238000010899 nucleation Methods 0.000 abstract 1
- 230000000052 comparative effect Effects 0.000 description 11
- NCJRLCWABWKAGX-UHFFFAOYSA-N [Si].[Ca].[Ba] Chemical compound [Si].[Ca].[Ba] NCJRLCWABWKAGX-UHFFFAOYSA-N 0.000 description 3
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- 238000004220 aggregation Methods 0.000 description 2
- 230000002776 aggregation Effects 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 239000004966 Carbon aerogel Substances 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 229910000997 High-speed steel Inorganic materials 0.000 description 1
- 108010038629 Molybdoferredoxin Proteins 0.000 description 1
- XBDQKXXYIPTUBI-UHFFFAOYSA-N Propionic acid Chemical compound CCC(O)=O XBDQKXXYIPTUBI-UHFFFAOYSA-N 0.000 description 1
- HBELESVMOSDEOV-UHFFFAOYSA-N [Fe].[Mo] Chemical compound [Fe].[Mo] HBELESVMOSDEOV-UHFFFAOYSA-N 0.000 description 1
- AHIVCQLQCIBVOS-UHFFFAOYSA-N [Fe].[W] Chemical compound [Fe].[W] AHIVCQLQCIBVOS-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010000 carbonizing Methods 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 238000009750 centrifugal casting Methods 0.000 description 1
- GSVIBLVMWGSPRZ-UHFFFAOYSA-N cerium iron Chemical compound [Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Fe].[Ce].[Ce] GSVIBLVMWGSPRZ-UHFFFAOYSA-N 0.000 description 1
- UPHIPHFJVNKLMR-UHFFFAOYSA-N chromium iron Chemical compound [Cr].[Fe] UPHIPHFJVNKLMR-UHFFFAOYSA-N 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- NNLJGFCRHBKPPJ-UHFFFAOYSA-N iron lanthanum Chemical compound [Fe].[La] NNLJGFCRHBKPPJ-UHFFFAOYSA-N 0.000 description 1
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 238000009718 spray deposition Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/04—Making ferrous alloys by melting
- C22C33/06—Making ferrous alloys by melting using master alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J13/00—Colloid chemistry, e.g. the production of colloidal materials or their solutions, not otherwise provided for; Making microcapsules or microballoons
- B01J13/0091—Preparation of aerogels, e.g. xerogels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/072—Treatment with gases
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/38—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for roll bodies
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/006—Making ferrous alloys compositions used for making ferrous alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/08—Making cast-iron alloys
- C22C33/10—Making cast-iron alloys including procedures for adding magnesium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/06—Cast-iron alloys containing chromium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
-
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Abstract
本发明公开了一种高韧性耐蚀合金石墨钢轧辊及其制备方法,涉及轧辊技术领域。本发明先利用酸化气凝胶络合氯化镧和氯化铈,以获得稀土‑酚醛气凝胶,再与其他生铁合金混合,通过梯度升温辅助间歇式脉冲气流进行熔融,细化晶粒,同时存在形核质点,大大提高轧辊的强度和韧性,并且在浇筑过程中,气凝胶吸附容纳熔液,连接构筑三维网状结构,进一步增强轧辊的强度和韧性,然后在轧辊表面依次沉积钛镍、石墨烯、钛镍,形成致密的夹心结构,提高轧辊的耐蚀性的同时,还能提高轧辊外层结构的韧性和硬度。
Description
技术领域
本发明涉及轧辊技术领域,具体为一种高韧性耐蚀合金石墨钢轧辊及其制备方法。
背景技术
轧辊是轧钢生产中的主要消耗备件,轧辊质量直接影响轧材表面质量、轧机作业率和轧材生产成本,提高轧辊质量,降低轧辊生产成本一直是轧辊生产企业不断关注的课题。现在国内生产的轧辊质量参差不齐,消枆指标高低不同,轧辊制造的方法在我国目前主要有以下几种:锻造轧辊、普通铸造轧辊、离心铸造轧辊、喷射成型轧辊、电渣重熔轧辊、连线浇筑外层成型、组合轧辊等。但是,在现有的高速钢复合轧辊生产技术中,在轧辊高硬度、高耐磨的同时,所伴随的就是轧辊的韧性差,在切分仞便出现掉块,造成无法正常生产,且现有的轧辊大多缺乏一种耐腐蚀层的保护,使得金属基体直接与空气中的杂质灰尘和氧气、水按触,大大增加腐蚀几率,提高维修费用和使用成本。
发明内容
本发明的目的在于提供一种高韧性耐蚀合金石墨钢轧辊及其制备方法,以解决现有技术中存在的问题。
为了解决上述技术问题,本发明提供如下技术方案:一种高韧性耐蚀合金石墨钢轧辊的制备方法,包括以下制备步骤:
(1)将湿凝胶浸入湿凝胶质量3~5倍的乙醇中,每8h置换一次,置换3次;再浸入湿凝胶质量3.1~8.3倍的(S)-2-甲基环氧乙烷-2-羧酸溶液,每8h置换一次,置换5次后,于90℃油浴中反应5~8h,浸入湿凝胶质量3~5倍的45℃的叔丁醇,每8h置换一次,置换6次,放入冰箱,预冻24h后,-40℃、真空度13~40Pa下冷冻干燥72h得粒径为0.45~0.6mm的羧基化酚醛气凝胶;
(2)将羧基化酚醛气凝胶、无水乙醇、去离子水按质量比2.5:59.2:75混合,得气凝胶悬浮液,50℃下,向气凝胶悬浮液加入气凝胶悬浮液质量0.02倍的稀土溶液,再加入氢氧化钠溶液至反应液pH为4~5,静置1.5~2.5h后,抽滤,依次用乙醇、蒸馏水洗涤3次,60℃烘干24h得稀土-酚醛气凝胶;
(3)按轧辊外层、芯部的具体成分要求进行分别冶炼,将稀土-酚醛气凝胶、废钢、铬铁、钨铁、钼铁、镍铁、硅钙钡合金、纯镁混合置于卧式熔炼设备,熔炼设备左右两端连有进气端电磁阀,加热至880~950℃,保温1h后,升温至1500~1550℃,保温至熔化后,升温至1550~1600℃,加入硼铁、钛铁,保温熔化后,加热至1630~1650℃,加入炉内钢水质量0.001~0.002倍的纯铝,保温4~10min,保温加热过程中,先开启左边电磁阀脉冲充气,气体中为氮气,脉冲充气至压力为0.2MPa后,停止充气5min,再开启脉冲充气至压力为0.2MPa,如此反复,然后出炉到装有稀土硅铁合金的钢包,稀土硅铁合金与钢包内钢水的质量比为0.25~0.45:100,1460~1520℃下离心浇筑外层钢水,离心浇筑的离心转速为600~780r/min,再撒入外层钢水质量0.02~0.1倍的玻璃渣,当外层钢水温度降至1180~1230℃,浇筑辊芯钢水,浇筑温度为1300~1350℃,浇筑完毕后,静置24~48h,取出铸件,放入热处理炉中,1100~1200℃热处理90~120min,出炉喷雾冷却至610~740℃,保温2~3h后,回炉升温至890~1000℃,保温4~7h后,出炉喷雾冷却至480~595℃,保温2~3h,回炉升温至770~870℃,保温4~7h后,空冷至室温,得轧辊;
(4)将轧辊采用400#、800#、1000#和1500#砂纸逐级打磨一次,用丙酮冲洗3~6min后,60℃烘干6h后,在轧辊刷电净液,刷镀电压10~12V、镀笔移动速率5~12m/min下刷镀1~3min后,用蒸馏水清洗3min,得电净轧辊;在电净轧辊刷活化液1,电压10~12V、镀笔移动速率5~12m/min下刷镀20~40s后,刷活化液2,电压13V、镀笔移动速率5~12m/min下刷镀40~65s,用蒸馏水清洗3min后,再刷钛镍镀液,镀笔移动速率5~10m/min、电压15V下刷镀30~50s,再以电压13V刷镀1~3min,5~15℃/min升温至650~850℃,保温2~3h得镀层厚度为15~20μm的钛镍轧辊;
(5)将无水乙醇、石墨粉按质量比8:1混合,400~600W超声10min,得石墨溶液;将石墨溶液旋涂在钛镍轧辊表面,厚度为20~30μm,静置24h后,置于真空腔,氩气氛围下,采用纳秒光纤激光器于功率为0.9~1.8W、脉宽150ns、扫描速度10mm/s、频率250KHz的条件下扫描2~5次,得石墨烯轧辊,再重复步骤(4)的步骤,制得高韧性耐蚀合金石墨钢轧辊。
进一步的,步骤(1)所述湿凝胶的制备方法为:将间苯二酚、甲醛、无水碳酸钠按质量比1:0.41:0.048混合,加入去离子水至固含量为15~30%,搅拌至固体完全溶解后,倒入模具中,放入烘箱,80℃下静置2h后,再于40℃静置3d。
进一步的,步骤(1)所述(S)-2-甲基环氧乙烷-2-羧酸溶液中(S)-2-甲基环氧乙烷-2-羧酸和乙醇的质量比为0.05~0.3:3~8。
进一步的,步骤(2)所述稀土溶液中氯化镧、氯化铈、无水乙醇、去离子水的质量比为2.5:1.2~2.5:39.5:50。
进一步的,步骤(3)所述轧辊外层的化学成分质量分数为:碳2.5~3.0%、硅1.0~1.2%、锰0.5~1.5%、磷0.01~0.1%、硫0.01~0.03%、镧0.001~0.003%、铈0.001~0.005%、硼1.9~2.2%、钼0.4~1.0%、铬1~2%、钙0.03~0.06%、钡0.03~0.06%,其余为铁。
进一步的,步骤(3)所述轧辊芯部的化学成分质量分数为:碳3.0~3.8%、硅1.8~2.0%、锰0.3~1.0%、磷0.01~0.1%、硫0.01~0.03%、镁0.03~0.06%、铬0.2~0.5%、钼0.1~0.3%、钙0.02~0.04%、钡0.02~0.04%、镧0.001~0.003%、铈0.001~0.005%,其余为铁。
进一步的,步骤(3)所述稀土硅铁合金的化学组成质量分数为铼24.7%,硅40%,锰1.0%,钙3.2%,钛0.3%、镍3.6%,其余为铁。
进一步的,步骤(4)所述电净液包括:氢氧化钠20~30g/L,磷酸钠50~70g/L,碳酸钠20~30g/L,氯化钠2g/L,pH为12。
进一步的,步骤(4)所述活化液1包括:盐酸10~30mL/L,氯化钠110~120g/L,其余为蒸馏水,pH为0.4~0.6;活化液2包括:硫酸70~90g/L,硫酸铵90~110g/L,磷酸3~5g/L,六氟化二硅4~6g/L,其余为蒸馏水,pH为0.5。
进一步的,步骤(4)所述钛镍镀液包括:六水合硫酸镍50g/L,六水合氯化镍10g/L,钛盐液50~125mL/L,硼酸40g/L,二水合柠檬酸三钠50g/L,2,5-吡咯烷二酮10g/L,其余为蒸馏水,pH为3.5~5.0;所述钛盐液中硫酸钛和蒸馏水的质量比为20~30:35~50。
与现有技术相比,本发明所达到的有益效果是;
本发明采用(S)-2-甲基环氧乙烷-2-羧酸的环氧基与酚醛气凝胶分子链中的羟基反应,从而在气凝胶表面及内部引入羧基,能够络合氯化镧和氯化铈,以获得稀土-酚醛气凝胶;然后将稀土-酚醛气凝胶与其他生铁合金混合,通过梯度升温进行熔融,气凝胶先进行炭化,同时高温裂解出碳氢小分子气体,与合金在高温区形成碳化物,从而形成硬质合金结构,提高轧辊芯部强度,又能提高轧辊的淬透性,同时,镧、铈与熔液中的氧、硫结合,与炭气凝胶共同形成形核质点,为合金晶相提供核心,使其形态更加圆整、分布更加均匀,此外,在熔融过程中,采用间歇式脉冲气流,促使熔液随不同方向的气流反复流动,从而细化晶粒,使其形貌从板条状变为颗粒状,大大提高轧辊的强度和韧性,同时,碳氢小分子气体随外界气体带动,迅速弥散各熔液中,防止团聚在一起,并且随着温度的逐渐升高,碳逐渐向石墨转变,利用表面多孔吸附熔液,呈孤立块状结构,代替网状碳化物,显著提高轧辊的强度和韧性。
本发明在轧辊表面电刷镀钛镍层,形成耐腐蚀保护基层,接着表面涂覆石墨溶液,激光辐照后形成石墨烯膜层,并且在激光辐照过程中,钛镍和石墨熔融结合,形成类扎钉结构,使得石墨烯膜层与钛镍层结合力强,间接提高轧辊的耐腐蚀性,最后在石墨烯膜层表面再次电刷镀钛镍层,形成钛镍-石墨烯-钛镍致密的夹心结构,防止腐蚀介质渗入,同时延长膜层的耐腐保护时间,还能提高轧辊外层结构的韧性和硬度。
具体实施方式
下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
(1)将间苯二酚、甲醛、无水碳酸钠按质量比1:0.41:0.048混合,加入去离子水至固含量为15%,搅拌至固体完全溶解后,倒入模具中,放入烘箱,80℃下静置2h后,再于40℃静置3d,得湿凝胶,浸入湿凝胶质量3倍的乙醇中,每8h置换一次,置换3次;再浸入湿凝胶质量3.1倍的(S)-2-甲基环氧乙烷-2-羧酸溶液,(S)-2-甲基环氧乙烷-2-羧酸溶液中(S)-2-甲基环氧乙烷-2-羧酸和乙醇的质量比为0.05:3,每8h置换一次,置换5次后,于90℃油浴中反应5h,浸入湿凝胶质量3倍的45℃的叔丁醇,每8h置换一次,置换6次,放入冰箱,预冻24h后,-40℃、真空度13Pa下冷冻干燥72h得粒径为0.45mm的羧基化酚醛气凝胶;
(2)将氯化镧、氯化铈、无水乙醇、去离子水按质量比2.5:1.2:39.5:50混合,搅拌溶解得稀土溶液;将羧基化酚醛气凝胶、无水乙醇、去离子水按质量比2.5:59.2:75混合,得气凝胶悬浮液,50℃下,向气凝胶悬浮液加入气凝胶悬浮液质量0.02倍的稀土溶液,再加入氢氧化钠溶液至反应液pH为4,静置1.5h后,抽滤,依次用乙醇、蒸馏水洗涤3次,60℃烘干24h得稀土-酚醛气凝胶;
(3)按轧辊外层、芯部的具体成分要求进行分别冶炼,将稀土-酚醛气凝胶、废钢、铬铁、钨铁、钼铁、镍铁、硅钙钡合金、纯镁混合置于卧式熔炼设备,熔炼设备左右两端连有进气端电磁阀,加热至880℃,保温1h后,升温至1500℃,保温至熔化后,升温至1550℃,加入硼铁、钛铁,保温熔化后,加热至1630℃,加入炉内钢水质量0.001倍的纯铝,保温4min,保温加热过程中,先开启左边电磁阀脉冲充气,气体中为氮气,脉冲充气至压力为0.2MPa后,停止充气5min,再开启脉冲充气至压力为0.2MPa,如此反复,然后出炉到装有稀土硅铁合金的钢包,稀土硅铁合金与钢包内钢水的质量比为0.25:100,1460℃下离心浇筑外层钢水,离心浇筑的离心转速为600r/min,再撒入外层钢水质量0.02倍的玻璃渣,当外层钢水温度降至1180℃,浇筑辊芯钢水,浇筑温度为1300℃,浇筑完毕后,静置24h,取出铸件,放入热处理炉中,1100℃热处理90min,出炉喷雾冷却至610℃,保温2h后,回炉升温至890℃,保温4h后,出炉喷雾冷却至480℃,保温2h,回炉升温至770℃,保温4h后,空冷至室温,得轧辊;
所述轧辊外层的化学成分质量分数为:碳2.5%、硅1.0%、锰0.5%、磷0.01%、硫0.01%、镧0.001%、铈0.001%、硼1.9%、钼0.4%、铬1%、钙0.03%、钡0.03%,其余为铁;
所述轧辊芯部的化学成分质量分数为:碳3.0%、硅1.8%、锰0.3%、磷0.01%、硫0.01%、镁0.03%、铬0.2%、钼0.1%、钙0.02%、钡0.02%、镧0.001%、铈0.001%,其余为铁;
所述稀土硅铁合金的化学组成质量分数为铼24.7%,硅40%,锰1.0%,钙3.2%,钛0.3%、镍3.6%,其余为铁
(4)将轧辊采用400#、800#、1000#和1500#砂纸逐级打磨一次,用丙酮冲洗3min后,60℃烘干6h后,在轧辊刷电净液,刷镀电压10V、镀笔移动速率5m/min下刷镀1min后,用蒸馏水清洗3min,得电净轧辊;在电净轧辊刷活化液1,电压10V、镀笔移动速率5m/min下刷镀20s后,刷活化液2,电压13V、镀笔移动速率5m/min下刷镀40s,用蒸馏水清洗3min后,再刷钛镍镀液,镀笔移动速率5m/min、电压15V下刷镀30s,再以电压13V刷镀1min,5℃/min升温至650℃,保温2h得镀层厚度为15μm的钛镍轧辊;
所述电净液包括:氢氧化钠20g/L,磷酸钠50g/L,碳酸钠20g/L,氯化钠2g/L,pH为12;
所述活化液1包括:盐酸10mL/L,氯化钠110g/L,其余为蒸馏水,pH为0.4;
所述活化液2包括:硫酸70g/L,硫酸铵90g/L,磷酸3g/L,六氟化二硅4g/L,其余为蒸馏水,pH为0.5;
所述钛镍镀液包括:六水合硫酸镍50g/L,六水合氯化镍10g/L,钛盐液50mL/L,硼酸40g/L,二水合柠檬酸三钠50g/L,2,5-吡咯烷二酮10g/L,其余为蒸馏水,pH为3.5,钛盐液中硫酸钛和蒸馏水的质量比为20:35;
(5)将无水乙醇、石墨粉按质量比8:1混合,400W超声10min,得石墨溶液;将石墨溶液旋涂在钛镍轧辊表面,厚度为20μm,静置24h后,置于真空腔,氩气氛围下,采用纳秒光纤激光器于功率为0.9W、脉宽150ns、扫描速度10mm/s、频率250KHz的条件下扫描2次,得石墨烯轧辊,再重复步骤(4)的步骤,制得高韧性耐蚀合金石墨钢轧辊。
实施例2
(1)将间苯二酚、甲醛、无水碳酸钠按质量比1:0.41:0.048混合,加入去离子水至固含量为22%,搅拌至固体完全溶解后,倒入模具中,放入烘箱,80℃下静置2h后,再于40℃静置3d,得湿凝胶,浸入湿凝胶质量4倍的乙醇中,每8h置换一次,置换3次;再浸入湿凝胶质5.7倍的(S)-2-甲基环氧乙烷-2-羧酸溶液,(S)-2-甲基环氧乙烷-2-羧酸溶液中(S)-2-甲基环氧乙烷-2-羧酸和乙醇的质量比为0.18:5.5,每8h置换一次,置换5次后,于90℃油浴中反应6.5h,浸入湿凝胶质量4倍的45℃的叔丁醇,每8h置换一次,置换6次,放入冰箱,预冻24h后,-40℃、真空度26Pa下冷冻干燥72h得粒径为0.52mm的羧基化酚醛气凝胶;
(2)将氯化镧、氯化铈、无水乙醇、去离子水按质量比2.5:1.8:39.5:50混合,搅拌溶解得稀土溶液;将羧基化酚醛气凝胶、无水乙醇、去离子水按质量比2.5:59.2:75混合,得气凝胶悬浮液,50℃下,向气凝胶悬浮液加入气凝胶悬浮液质量0.02倍的稀土溶液,再加入氢氧化钠溶液至反应液pH为4.5,静置2h后,抽滤,依次用乙醇、蒸馏水洗涤3次,60℃烘干24h得稀土-酚醛气凝胶;
(3)按轧辊外层、芯部的具体成分要求进行分别冶炼,将稀土-酚醛气凝胶、废钢、铬铁、钨铁、钼铁、镍铁、硅钙钡合金、纯镁混合置于卧式熔炼设备,熔炼设备左右两端连有进气端电磁阀,加热至915℃,保温1h后,升温至1525℃,保温至熔化后,升温至1575℃,加入硼铁、钛铁,保温熔化后,加热至1640℃,加入炉内钢水质量0.0015倍的纯铝,保温7min,保温加热过程中,先开启左边电磁阀脉冲充气,气体中为氮气,脉冲充气至压力为0.2MPa后,停止充气5min,再开启脉冲充气至压力为0.2MPa,如此反复,然后出炉到装有稀土硅铁合金的钢包,稀土硅铁合金与钢包内钢水的质量比为0.35:100,1490℃下离心浇筑外层钢水,离心浇筑的离心转速为690r/min,再撒入外层钢水质量0.06倍的玻璃渣,当外层钢水温度降至1205℃,浇筑辊芯钢水,浇筑温度为1325℃,浇筑完毕后,静置36h,取出铸件,放入热处理炉中,1150℃热处理105min,出炉喷雾冷却至675℃,保温2.5h后,回炉升温至950℃,保温5.5h后,出炉喷雾冷却至535℃,保温2.5h,回炉升温至820℃,保温5.5h后,空冷至室温,得轧辊;
所述轧辊外层的化学成分质量分数为:碳2.8%、硅1.1%、锰1.0%、磷0.06%、硫0.02%、镧0.002%、铈0.003%、硼2.0%、钼0.6%、铬1.5%、钙0.05%、钡0.045%,其余为铁;
所述轧辊芯部的化学成分质量分数为:碳3.4%、硅1.9%、锰0.65%、磷0.04%、硫0.015%、镁0.045%、铬0.4%、钼0.2%、钙0.03%、钡0.03%、镧0.002%、铈0.002%,其余为铁;
所述稀土硅铁合金的化学组成质量分数为铼24.7%,硅40%,锰1.0%,钙3.2%,钛0.3%、镍3.6%,其余为铁;
(4)将轧辊采用400#、800#、1000#和1500#砂纸逐级打磨一次,用丙酮冲洗4min后,60℃烘干6h后,在轧辊刷电净液,刷镀电压11V、镀笔移动速率8m/min下刷镀2min后,用蒸馏水清洗3min,得电净轧辊;在电净轧辊刷活化液1,电压11V、镀笔移动速率8m/min下刷镀30s后,刷活化液2,电压13V、镀笔移动速率8m/min下刷镀53s,用蒸馏水清洗3min后,再刷钛镍镀液,镀笔移动速率7m/min、电压15V下刷镀40s,再以电压13V刷镀2min,10℃/min升温至750℃,保温2.5h得镀层厚度为17.5μm的钛镍轧辊;
所述电净液包括:氢氧化钠25g/L,磷酸钠60g/L,碳酸钠25g/L,氯化钠2g/L,pH为12;
所述活化液1包括:盐酸20mL/L,氯化钠115g/L,其余为蒸馏水,pH为0.5;
所述活化液2包括:硫酸80g/L,硫酸铵100g/L,磷酸4g/L,六氟化二硅5g/L,其余为蒸馏水,pH为0.5;
所述钛镍镀液包括:六水合硫酸镍50g/L,六水合氯化镍10g/L,钛盐液87mL/L,硼酸40g/L,二水合柠檬酸三钠50g/L,2,5-吡咯烷二酮10g/L,其余为蒸馏水,pH为4.5,钛盐液中硫酸钛和蒸馏水的质量比为25:42.5;
(5)将无水乙醇、石墨粉按质量比8:1混合,500W超声10min,得石墨溶液;将石墨溶液旋涂在钛镍轧辊表面,厚度为25μm,静置24h后,置于真空腔,氩气氛围下,采用纳秒光纤激光器于功率为1.3W、脉宽150ns、扫描速度10mm/s、频率250KHz的条件下扫描3次,得石墨烯轧辊,再重复步骤(4)的步骤,制得高韧性耐蚀合金石墨钢轧辊。
实施例3
(1)将间苯二酚、甲醛、无水碳酸钠按质量比1:0.41:0.048混合,加入去离子水至固含量为30%,搅拌至固体完全溶解后,倒入模具中,放入烘箱,80℃下静置2h后,再于40℃静置3d,得湿凝胶,浸入湿凝胶质量5倍的乙醇中,每8h置换一次,置换3次;再浸入湿凝胶质量8.3倍的(S)-2-甲基环氧乙烷-2-羧酸溶液,(S)-2-甲基环氧乙烷-2-羧酸溶液中(S)-2-甲基环氧乙烷-2-羧酸和乙醇的质量比为0.3:8,每8h置换一次,置换5次后,于90℃油浴中反应8h,浸入湿凝胶质量5倍的45℃的叔丁醇,每8h置换一次,置换6次,放入冰箱,预冻24h后,-40℃、真空度40Pa下冷冻干燥72h得粒径为0.6mm的羧基化酚醛气凝胶;
(2)将氯化镧、氯化铈、无水乙醇、去离子水按质量比2.5:2.5:39.5:50混合,搅拌溶解得稀土溶液;将羧基化酚醛气凝胶、无水乙醇、去离子水按质量比2.5:59.2:75混合,得气凝胶悬浮液,50℃下,向气凝胶悬浮液加入气凝胶悬浮液质量0.02倍的稀土溶液,再加入氢氧化钠溶液至反应液pH为5,静置2.5h后,抽滤,依次用乙醇、蒸馏水洗涤3次,60℃烘干24h得稀土-酚醛气凝胶;
(3)按轧辊外层、芯部的具体成分要求进行分别冶炼,将稀土-酚醛气凝胶、废钢、铬铁、钨铁、钼铁、镍铁、硅钙钡合金、纯镁混合置于卧式熔炼设备,熔炼设备左右两端连有进气端电磁阀,加热至950℃,保温1h后,升温至1550℃,保温至熔化后,升温至1600℃,加入硼铁、钛铁,保温熔化后,加热至1650℃,加入炉内钢水质量0.002倍的纯铝,保温10min,保温加热过程中,先开启左边电磁阀脉冲充气,气体中为氮气,脉冲充气至压力为0.2MPa后,停止充气5min,再开启脉冲充气至压力为0.2MPa,如此反复,然后出炉到装有稀土硅铁合金的钢包,稀土硅铁合金与钢包内钢水的质量比为0.45:100,1520℃下离心浇筑外层钢水,离心浇筑的离心转速为780r/min,再撒入外层钢水质量0.1倍的玻璃渣,当外层钢水温度降至1230℃,浇筑辊芯钢水,浇筑温度为1350℃,浇筑完毕后,静置48h,取出铸件,放入热处理炉中,1200℃热处理120min,出炉喷雾冷却至740℃,保温3h后,回炉升温至1000℃,保温7h后,出炉喷雾冷却至595℃,保温3h,回炉升温至870℃,保温7h后,空冷至室温,得轧辊;
所述轧辊外层的化学成分质量分数为:碳3.0%、硅1.2%、锰1.5%、磷0.1%、硫0.03%、镧0.003%、铈0.005%、硼2.2%、钼1.0%、铬2%、钙0.06%、钡0.06%,其余为铁;
所述轧辊芯部的化学成分质量分数为:碳3.8%、硅2.0%、锰1.0%、磷0.1%、硫0.03%、镁0.06%、铬0.5%、钼0.3%、钙0.04%、钡0.04%、镧0.003%、铈0.005%,其余为铁;
所述稀土硅铁合金的化学组成质量分数为铼24.7%,硅40%,锰1.0%,钙3.2%,钛0.3%、镍3.6%,其余为铁;
(4)将轧辊采用400#、800#、1000#和1500#砂纸逐级打磨一次,用丙酮冲洗6min后,60℃烘干6h后,在轧辊刷电净液,刷镀电压12V、镀笔移动速率12m/min下刷镀3min后,用蒸馏水清洗3min,得电净轧辊;在电净轧辊刷活化液1,电压12V、镀笔移动速率12m/min下刷镀40s后,刷活化液2,电压13V、镀笔移动速率12m/min下刷镀65s,用蒸馏水清洗3min后,再刷钛镍镀液,镀笔移动速率10m/min、电压15V下刷镀50s,再以电压13V刷镀3min,15℃/min升温至850℃,保温3h得镀层厚度为20μm的钛镍轧辊;
所述电净液包括:氢氧化钠30g/L,磷酸钠70g/L,碳酸钠30g/L,氯化钠2g/L,pH为12;
所述活化液1包括:盐酸30mL/L,氯化钠120g/L,其余为蒸馏水,pH为0.6;
所述活化液2包括:硫酸90g/L,硫酸铵110g/L,磷酸5g/L,六氟化二硅6g/L,其余为蒸馏水,pH为0.5;
所述钛镍镀液包括:六水合硫酸镍50g/L,六水合氯化镍10g/L,钛盐液125mL/L,硼酸40g/L,二水合柠檬酸三钠50g/L,2,5-吡咯烷二酮10g/L,其余为蒸馏水,pH为5.0,钛盐液中硫酸钛和蒸馏水的质量比为30:50;
(5)将无水乙醇、石墨粉按质量比8:1混合,600W超声10min,得石墨溶液;将石墨溶液旋涂在钛镍轧辊表面,厚度为30μm,静置24h后,置于真空腔,氩气氛围下,采用纳秒光纤激光器于功率为1.8W、脉宽150ns、扫描速度10mm/s、频率250KHz的条件下扫描5次,得石墨烯轧辊,再重复步骤(4)的步骤,制得高韧性耐蚀合金石墨钢轧辊。
对比例1
对比例1与实施例2的区别在于无步骤(1)、(2),步骤(3)改为:按轧辊外层、芯部的具体成分要求进行分别冶炼,将铈铁、镧铁、废钢、铬铁、钨铁、钼铁、镍铁、硅钙钡合金、纯镁混合置于卧式熔炼设备,熔炼设备左右两端连有进气端电磁阀,升温至1525℃,保温至熔化后,升温至1575℃,加入硼铁、钛铁,保温熔化后,加热至1640℃,加入炉内钢水质量0.0015倍的纯铝,保温7min,保温加热过程中,先开启左边电磁阀脉冲充气,气体中为氮气,脉冲充气至压力为0.2MPa后,停止充气5min,再开启脉冲充气至压力为0.2MPa,如此反复,然后出炉到装有稀土硅铁合金的钢包,稀土硅铁合金与钢包内钢水的质量比为0.35:100,1490℃下离心浇筑外层钢水,离心浇筑的离心转速为690r/min,再撒入外层钢水质量0.06倍的玻璃渣,当外层钢水温度降至1205℃,浇筑辊芯钢水,浇筑温度为1325℃,浇筑完毕后,静置36h,取出铸件,放入热处理炉中,1150℃热处理105min,出炉喷雾冷却至675℃,保温2.5h后,回炉升温至950℃,保温5.5h后,出炉喷雾冷却至535℃,保温2.5h,回炉升温至820℃,保温5.5h后,空冷至室温,得轧辊。其余步骤同实施例2。
对比例2
对比例2与实施例2的区别在于步骤(3)的不同,将步骤(3)改为:按轧辊外层、芯部的具体成分要求进行分别冶炼,将稀土-酚醛气凝胶、废钢、铬铁、钨铁、钼铁、镍铁、硅钙钡合金、纯镁混合置于卧式熔炼设备,熔炼设备左右两端连有进气端电磁阀,加热至915℃,保温1h后,升温至1525℃,保温至熔化后,升温至1575℃,加入硼铁、钛铁,保温熔化后,加热至1640℃,加入炉内钢水质量0.0015倍的纯铝,保温7min,然后出炉到装有稀土硅铁合金的钢包,稀土硅铁合金与钢包内钢水的质量比为0.35:100,1490℃下离心浇筑外层钢水,离心浇筑的离心转速为690r/min,再撒入外层钢水质量0.06倍的玻璃渣,当外层钢水温度降至1205℃,浇筑辊芯钢水,浇筑温度为1325℃,浇筑完毕后,静置36h,取出铸件,放入热处理炉中,1150℃热处理105min,出炉喷雾冷却至675℃,保温2.5h后,回炉升温至950℃,保温5.5h后,出炉喷雾冷却至535℃,保温2.5h,回炉升温至820℃,保温5.5h后,空冷至室温,得轧辊。其余步骤同实施例2。
对比例3
对比例3与实施例2的区别在于无步骤(4),步骤(5)改为:将无水乙醇、石墨粉按质量比8:1混合,500W超声10min,得石墨溶液;将石墨溶液旋涂在轧辊表面,厚度为25μm,静置24h后,置于真空腔,氩气氛围下,采用纳秒光纤激光器于功率为1.3W、脉宽150ns、扫描速度10mm/s、频率250KHz的条件下扫描3次,得高韧性耐蚀合金石墨钢轧辊。其余步骤同实施例2。
效果例
下表1中给出了采用本发明实施例1至3与对比例1至3的高韧性耐蚀合金石墨钢轧辊的性能分析结果。
表1
冲击韧性(J/cm2) | 硬度(HRC) | 在质最分数为3%的氯化钠溶液中的腐蚀率(g/m2h-1) | |
实施例1 | 21.5 | 77.3 | 0.12 |
实施例2 | 21.6 | 78.9 | 0.11 |
实施例3 | 21.3 | 76.9 | 0.13 |
对比例1 | 15.7 | 68.7 | 0.15 |
对比例2 | 16.0 | 70.1 | 0.15 |
对比例3 | 17.9 | 72.2 | 0.43 |
从实施例与对比例的实验数据比较可发现,本发明采用稀土-酚醛气凝胶与其他生铁合金混合,通过梯度升温进行熔融,气凝胶先进行炭化,同时高温裂解出碳氢小分子气体,与合金在高温区形成碳化物,提高轧辊芯部强度,并且采用间歇式脉冲气流,促使熔液随不同方向的气流反复流动,从而细化晶粒,使其形貌从板条状变为颗粒状,大大提高轧辊的强度和韧性,同时,碳氢小分子气体随外界气体带动,迅速弥散各熔液中,防止团聚在一起,浇筑过程中,炭化后的气凝胶利用多孔结构,吸附熔液,在轧辊基体中连接构筑三维网状结构,有效发挥气凝胶强化作用,显著提高轧辊的强度和韧性,然后在轧辊表面形成钛镍-石墨烯-钛镍致密的夹心结构,防止腐蚀介质渗入,还能提高轧辊外层结构的韧性和硬度。
对于本领域技术人员而言,显然本发明不限于上述示范性实施例的细节,而且在不背离本发明的精神或基本特征的情况下,能够以其他的具体形式实现本发明。因此,无论从哪一点来看,均应将实施例看作是示范性的,而且是非限制性的,本发明的范围由所附权利要求而不是上述说明限定,因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。不应将权利要求中的任何标记视为限制所涉及的权利要求。
Claims (10)
1.一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,包括以下制备步骤:
(1)将湿凝胶浸入湿凝胶质量3~5倍的乙醇中,每8h置换一次,置换3次;再浸入湿凝胶质量3.1~8.3倍的(S)-2-甲基环氧乙烷-2-羧酸溶液,每8h置换一次,置换5次后,于90℃油浴中反应5~8h,浸入湿凝胶质量3~5倍的45℃的叔丁醇,每8h置换一次,置换6次,放入冰箱,预冻24h后,-40℃、真空度13~40Pa下冷冻干燥72h得粒径为0.45~0.6mm的羧基化酚醛气凝胶;
(2)将羧基化酚醛气凝胶、无水乙醇、去离子水按质量比2.5:59.2:75混合,得气凝胶悬浮液,50℃下,向气凝胶悬浮液加入气凝胶悬浮液质量0.02倍的稀土溶液,再加入氢氧化钠溶液至反应液pH为4~5,静置1.5~2.5h后,抽滤,依次用乙醇、蒸馏水洗涤3次,60℃烘干24h得稀土-酚醛气凝胶;
(3)按轧辊外层、芯部的具体成分要求进行分别冶炼,将稀土-酚醛气凝胶、废钢、铬铁、钨铁、钼铁、镍铁、硅钙钡合金、纯镁混合置于卧式熔炼设备,熔炼设备左右两端连有进气端电磁阀,加热至880~950℃,保温1h后,升温至1500~1550℃,保温至熔化后,升温至1550~1600℃,加入硼铁、钛铁,保温熔化后,加热至1630~1650℃,加入炉内钢水质量0.001~0.002倍的纯铝,保温4~10min,保温加热过程中,先开启左边电磁阀脉冲充气,气体中为氮气,脉冲充气至压力为0.2MPa后,停止充气5min,再开启脉冲充气至压力为0.2MPa,如此反复,然后出炉到装有稀土硅铁合金的钢包,稀土硅铁合金与钢包内钢水的质量比为0.25~0.45:100,1460~1520℃下离心浇筑外层钢水,离心浇筑的离心转速为600~780r/min,再撒入外层钢水质量0.02~0.1倍的玻璃渣,当外层钢水温度降至1180~1230℃,浇筑辊芯钢水,浇筑温度为1300~1350℃,浇筑完毕后,静置24~48h,取出铸件,放入热处理炉中,1100~1200℃热处理90~120min,出炉喷雾冷却至610~740℃,保温2~3h后,回炉升温至890~1000℃,保温4~7h后,出炉喷雾冷却至480~595℃,保温2~3h,回炉升温至770~870℃,保温4~7h后,空冷至室温,得轧辊;
(4)将轧辊采用400#、800#、1000#和1500#砂纸逐级打磨一次,用丙酮冲洗3~6min后,60℃烘干6h后,在轧辊刷电净液,刷镀电压10~12V、镀笔移动速率5~12m/min下刷镀1~3min后,用蒸馏水清洗3min,得电净轧辊;在电净轧辊刷活化液1,电压10~12V、镀笔移动速率5~12m/min下刷镀20~40s后,刷活化液2,电压13V、镀笔移动速率5~12m/min下刷镀40~65s,用蒸馏水清洗3min后,再刷钛镍镀液,镀笔移动速率5~10m/min、电压15V下刷镀30~50s,再以电压13V刷镀1~3min,5~15℃/min升温至650~850℃,保温2~3h得镀层厚度为15~20μm的钛镍轧辊;
(5)将无水乙醇、石墨粉按质量比8:1混合,400~600W超声10min,得石墨溶液;将石墨溶液旋涂在钛镍轧辊表面,厚度为20~30μm,静置24h后,置于真空腔,氩气氛围下,采用纳秒光纤激光器于功率为0.9~1.8W、脉宽150ns、扫描速度10mm/s、频率250KHz的条件下扫描2~5次,得石墨烯轧辊,再重复步骤(4)的步骤,制得高韧性耐蚀合金石墨钢轧辊。
2.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(1)所述湿凝胶的制备方法为:将间苯二酚、甲醛、无水碳酸钠按质量比1:0.41:0.048混合,加入去离子水至固含量为15~30%,搅拌至固体完全溶解后,倒入模具中,放入烘箱,80℃下静置2h后,再于40℃静置3d。
3.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(1)所述(S)-2-甲基环氧乙烷-2-羧酸溶液中(S)-2-甲基环氧乙烷-2-羧酸和乙醇的质量比为0.05~0.3:3~8。
4.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(2)所述稀土溶液中氯化镧、氯化铈、无水乙醇、去离子水的质量比为2.5:1.2~2.5:39.5:50。
5.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(3)所述轧辊外层的化学成分质量分数为:碳2.5~3.0%、硅1.0~1.2%、锰0.5~1.5%、磷0.01~0.1%、硫0.01~0.03%、镧0.001~0.003%、铈0.001~0.005%、硼1.9~2.2%、钼0.4~1.0%、铬1~2%、钙0.03~0.06%、钡0.03~0.06%,其余为铁。
6.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(3)所述轧辊芯部的化学成分质量分数为:碳3.0~3.8%、硅1.8~2.0%、锰0.3~1.0%、磷0.01~0.1%、硫0.01~0.03%、镁0.03~0.06%、铬0.2~0.5%、钼0.1~0.3%、钙0.02~0.04%、钡0.02~0.04%、镧0.001~0.003%、铈0.001~0.005%,其余为铁。
7.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(3)所述稀土硅铁合金的化学组成质量分数为铼24.7%,硅40%,锰1.0%,钙3.2%,钛0.3%、镍3.6%,其余为铁。
8.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(4)所述电净液包括:氢氧化钠20~30g/L,磷酸钠50~70g/L,碳酸钠20~30g/L,氯化钠2g/L,pH为12。
9.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(4)所述活化液1包括:盐酸10~30mL/L,氯化钠110~120g/L,其余为蒸馏水,pH为0.4~0.6;活化液2包括:硫酸70~90g/L,硫酸铵90~110g/L,磷酸3~5g/L,六氟化二硅4~6g/L,其余为蒸馏水,pH为0.5。
10.根据权利要求1所述的一种高韧性耐蚀合金石墨钢轧辊的制备方法,其特征在于,步骤(4)所述钛镍镀液包括:六水合硫酸镍50g/L,六水合氯化镍10g/L,钛盐液50~125mL/L,硼酸40g/L,二水合柠檬酸三钠50g/L,2,5-吡咯烷二酮10g/L,其余为蒸馏水,pH为3.5~5.0;所述钛盐液中硫酸钛和蒸馏水的质量比为20~30:35~50。
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