CN117364012A - 一种高压柱塞泵用高耐磨自润滑柱塞制备方法及柱塞 - Google Patents
一种高压柱塞泵用高耐磨自润滑柱塞制备方法及柱塞 Download PDFInfo
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- 238000002360 preparation method Methods 0.000 title claims abstract description 14
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 73
- 239000010949 copper Substances 0.000 claims abstract description 56
- 229910052802 copper Inorganic materials 0.000 claims abstract description 56
- 238000005245 sintering Methods 0.000 claims abstract description 37
- 239000011812 mixed powder Substances 0.000 claims abstract description 28
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims abstract description 25
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 19
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 19
- 239000010959 steel Substances 0.000 claims abstract description 19
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 17
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000010705 motor oil Substances 0.000 claims abstract description 12
- 229910000906 Bronze Inorganic materials 0.000 claims abstract description 8
- 239000010974 bronze Substances 0.000 claims abstract description 8
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 claims abstract description 8
- 238000011049 filling Methods 0.000 claims abstract description 8
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 8
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- 238000004663 powder metallurgy Methods 0.000 claims description 7
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- 238000003754 machining Methods 0.000 claims description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 5
- 239000011248 coating agent Substances 0.000 claims description 5
- 238000000576 coating method Methods 0.000 claims description 5
- 239000001257 hydrogen Substances 0.000 claims description 5
- 229910052739 hydrogen Inorganic materials 0.000 claims description 5
- 238000007654 immersion Methods 0.000 claims description 5
- 229910052757 nitrogen Inorganic materials 0.000 claims description 5
- 230000001050 lubricating effect Effects 0.000 abstract description 6
- 239000000463 material Substances 0.000 description 14
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- 229910002804 graphite Inorganic materials 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 1
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- 235000014366 other mixer Nutrition 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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Abstract
本发明公开了一种高压柱塞泵用高耐磨自润滑柱塞制备方法及柱塞,包括以下步骤:步骤一,准备好钢质圆筒形支承体,先将支承体外表面进行喷砂除锈,然后采用等离子喷涂的方式在支承体外表面形成一层锡青铜薄层;步骤二,将镍粉、铁粉、铜粉、锡粉和石墨粉投入滚筒搅拌器中搅拌均匀;步骤三,将支承体放入外径稍大的圆筒形模具正中间,再将混合粉末填充至两者空隙中,刮除多余混合粉末后一起放至通过式网带炉中进行烧结。以45号钢作为支承体,保证了柱塞的高强度和高刚性,同时也将柱塞与缸体之间的热膨胀系数不同的问题减至最小;以镍粉、铁粉、铜粉、锡粉和石墨粉烧结而成的铜基摩擦层在吸取机油后具备优秀的润滑性能。
Description
技术领域
本发明涉及柱塞加工技术领域,更具体地说,涉及一种高压柱塞泵用高耐磨自润滑柱塞制备方法及柱塞。
背景技术
高压柱塞泵作为液压系统中的动力元件和核心装备,近年来因结构独特、高效率、高耐压、可实现多变量功能等特点在液压元件中脱颖而出,可用于坦克、潜艇、石油开采和载重机等领域。高压柱塞泵依靠柱塞在缸体中往复运动,使密封工作容腔的容积发生变化来实现吸油、压油,其使用压力一般在10MPa~100MPa之间。高压柱塞泵中的柱塞由于在较高工作压力的环境中作往复运动,这就要求柱塞必须具有高的刚性和润滑性能,才能满足使用需求。
国内外一般采用高强度铸造铜合金作为柱塞材料,但是此类材质的柱塞应用在高压柱塞泵当中,有着严重缺点。例如,柱塞与缸体材质不一样,膨胀系数不一致,容易造成配合过盈;在高压环境下,往复运动使得铜合金柱塞热胀而产生运动不畅;另外,就是此类合金的润滑性能不尽理想,这就限制了此类材料在高压柱塞泵中的应用。目前,也有人尝试用复合材料制备高压柱塞泵柱塞或者缸体,但是却不能保证摩擦层和支承体保持高的结合强度,摩擦层会发生开裂和脱层。很显然,对于具有圆柱面的柱塞而言,两种材料的复合难度要比平面的更加大,所以该类高压柱塞泵用柱塞及其制备技术一直以来是我国的短板,制约了相关领域的发展。
发明内容
针对现有技术中存在的问题,本发明的目的在于提供一种具备高的强度、刚性及润滑性能的高压柱塞泵用高耐磨自润滑柱塞制备方法及柱塞,
为解决上述问题,本发明采用如下的技术方案。一种高压柱塞泵用高耐磨自润滑柱塞制备方法,包括以下步骤:
步骤一,准备好钢质圆筒形支承体,先将支承体外表面进行喷砂除锈,然后采用等离子喷涂的方式在支承体外表面形成一层锡青铜薄层;
步骤二,将粒度为40~200目的镍粉、铁粉、铜粉、锡粉和石墨粉投入滚筒搅拌器中搅拌均匀,搅拌时间为1~2h,形成混合粉末;
步骤三,将支承体放入外径稍大的圆筒形模具正中间,支撑体外壁与模具内壁之间留有空隙,再将混合粉末填充至两者空隙中,刮除多余混合粉末后一起放至通过式网带炉中进行烧结,通过式网带炉中充有氮气和氢气;烧结完冷却至室温后,混合粉末形成铜基摩擦层覆在支承体外表面进而得到柱塞粗坯,再将柱塞粗坯与模具分离;
步骤四,将初步烧结好的柱塞粗坯放入压力机分体模具中,进一步进行压制,使得铜基摩擦层压实在支承体外表面,得到柱塞坯;
步骤五,将压制好的柱塞坯再次放入通过式网带炉中进行回火,烧结气氛与初次烧结相同,后冷却至80℃以下取出;
步骤六,将烧结好的柱塞坯进行精密机加工,使得铜基摩擦层厚度为1~3mm,得到柱塞;
步骤七,将机加工好的柱塞浸入真空吸油机中,使得真空吸油机中的机油填充至铜基摩擦层中的孔隙中。
在一些实施例中,所述步骤三中,烧结温度为950~1000℃,烧结时间为1~1.5h。
在一些实施例中,所述步骤四中,压制力为200~220N/mm2;
在一些实施例中,所述步骤五中,烧结温度为950~1300℃,烧结时间为1~1.5h。
在一些实施例中,所述步骤七中,浸油时间为10~30min。
在一些实施例中,以所述铜基摩擦层的总重量为100%计,各组分重量百分含量如下列组分:镍粉:10~15wt%,铁粉:50~60wt%,铜粉:10~30wt%,锡粉:10~15wt%,其余为石墨粉。
一种高压柱塞泵用高耐磨自润滑柱塞,包括铜基摩擦层和支承体,所述铜基摩擦层是用镍粉、铁粉、铜粉、锡粉和石墨粉通过粉末冶金的方法复合于圆筒形钢质支承体的外表面,所述铜基摩擦层的孔隙中填充有润滑剂。
在一些实施例中,所述润滑剂采用机油。
在一些实施例中,所述圆筒形支承体为45号钢材质。
在一些实施例中,述铜基摩擦层厚度为1~3mm。
本发明技术方案,具有如下优点:
(1)本发明提供的高压柱塞泵用高耐磨自润滑柱塞,以45号钢作为支承体,保证了柱塞的高强度和高刚性,同时也将柱塞与缸体之间的热膨胀系数不同的问题减至最小;以镍粉、铁粉、铜粉、锡粉和石墨粉烧结而成的铜基摩擦层在吸取机油后具备优秀的润滑性能。本发明提供的高压柱塞泵用高耐磨自润滑柱塞的硬度可达120~140HB,支承体与铜基摩擦层的结合强度可达45~70MPa,含油率≥12%。
(2)本发明提供的高压柱塞泵用高耐磨自润滑柱塞的制备方法,先将支承体外表面进行喷砂除锈,然后采用等离子喷涂的方式在支承体外表面形成一层锡青铜薄层,可以有效促使混合粉末烧结后与支承体结合在一起,还可保护支承体表面不受腐蚀和起到中间缓冲层的作用。
(3)本发明提供的高压柱塞泵用高耐磨自润滑柱塞的制备方法,采用烧结-压制-回火的工艺,使得铜基摩擦层更为牢固的结合在支承体外表面,解决了铜基摩擦层在烧结后容易开裂和脱层的难题。
(4)采用粉末冶金方法,在混料时加入了固体润滑剂石墨,所占比例高,更大幅度的改善了材料的减摩性能;且烧结材料具有多孔性,吸油后材料含油率高,材料更具自润滑性能,减摩性能特佳,还能减震和降低噪声;另外,可获得无偏析的铜基摩擦层。
附图说明
图1为本发明实施例中的高压柱塞泵用高耐磨自润滑柱塞的示意图。
图中标号说明:
1、铜基摩擦层;2、支承体。
具体实施方式
下面将结合本发明实施例中的附图,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。
本发明提供的一种高压柱塞泵用高耐磨自润滑柱塞,参考图1,包括了铜基摩擦层1和支承体2,所述铜基摩擦层是用镍粉、铁粉、铜粉、锡粉和石墨粉通过粉末冶金的方法复合于圆筒形钢质支承体的外表面,所述铜基摩擦层孔隙中填充机油作为润滑剂。所述圆筒形支承体为45号钢材质。所述铜基摩擦层厚度为1~3mm。本发明提供的高压柱塞泵用高耐磨自润滑柱塞中钢质支承体与铜基摩擦层结合紧密,拥有高的强度、刚性和润滑性能,硬度可达120~140HB,结合强度可达45~70MPa,含油率≥12%。
本发明还提供了一种高压柱塞泵用高耐磨自润滑柱塞制备方法,包括以下步骤:
步骤一,准备好钢质圆筒形支承体,先将支承体外表面进行喷砂除锈,然后采用等离子喷涂的方式在支承体外表面形成一层锡青铜薄层;可以理解的,除锈后等离子喷涂所形成的锡青铜薄层可以对支承体表面不受腐蚀和中间缓冲层的作用,而且可以有效促使混合粉末烧结后与支承体结合在一起。
步骤二,将粒度为40~200目的镍粉、铁粉、铜粉、锡粉和石墨粉投入滚筒搅拌器中搅拌均匀,搅拌时间为1~2h,形成混合粉末;可以理解的,该步骤为混料,滚筒搅拌器只是搅拌工具,当然也可以采用手工或其他的搅拌器进行搅拌;
步骤三,将支承体放入外径稍大的圆筒形模具正中间,支撑体外壁与模具内壁之间留有空隙,再将混合粉末填充至两者空隙中,刮除多余混合粉末后一起放至通过式网带炉中进行烧结,烧结温度为950~1000℃,烧结时间为1~1.5h,通过式网带炉中充有氮气和氢气;烧结完冷却至室温后,混合粉末形成铜基摩擦层覆在支承体外表面进而得到柱塞粗坯,再将柱塞粗坯与模具分离;可以理解的,粉末冶金方法具备以下优势:在混料时加入了固体润滑剂石墨,所占比例高,更大幅度的改善了材料的减摩性能。
步骤四,将初步烧结好的柱塞粗坯放入压力机分体模具中,进一步进行压制,使得铜基摩擦层压实在支承体外表面,其中,压制力为200~220N/mm2;得到柱塞坯;
步骤五,将压制好的柱塞坯再次放入通过式网带炉中进行回火,烧结气氛与初次烧结相同,烧结温度为950~1300℃,烧结时间为1~1.5h,后冷却至80℃以下取出;可以理解的,回火的目的是使得压制后的铜基摩擦层更加致密,进一步提高铜基摩擦层与支承体的结合强度。
步骤六,将烧结好的柱塞坯进行精密机加工,使得铜基摩擦层厚度为1~3mm,得到柱塞;可以理解的,通过精密加工来提高柱塞的表面精度。
步骤七,将机加工好的柱塞浸入真空吸油机中,使得真空吸油机中的机油填充至铜基摩擦层中的孔隙中,浸油时间为10~30min。可以理解的,烧结材料具有多孔性,其表面和内部均存在孔隙,吸油后材料含油率高,材料更具自润滑性能,减摩性能特佳,还能减震和降低噪声。
实施例1:
一种高压柱塞泵用高耐磨自润滑柱塞,包括了铜基摩擦层1和支承体2,所述铜基摩擦层是用镍粉、铁粉、铜粉、锡粉和石墨粉通过粉末冶金的方法复合于圆筒形钢质支承体的外表面,所述铜基摩擦层孔隙中填充机油作为润滑剂。所述圆筒形支承体为45号钢材质。所述铜基摩擦层厚度为1mm。
一种高压柱塞泵用高耐磨自润滑柱塞制备方法,包括以下步骤:
步骤一,准备好钢质圆筒形支承体,先将支承体外表面进行喷砂除锈,然后采用等离子喷涂的方式在支承体外表面形成一层锡青铜薄层。
步骤二,将粒度为100目的镍粉、铁粉、铜粉、锡粉和石墨粉投入滚筒搅拌器中搅拌均匀,其中,镍粉所占比例为10wt%,铁粉50wt%,铜粉10wt%,锡粉10wt%,其余为石墨粉;搅拌时间为1.5h。
步骤三,将支承体放入外径稍大的圆筒形模具正中间,支撑体外壁与模具内壁之间留有空隙,再将混合粉末填充至两者空隙中,刮除多余混合粉末后一起放至通过式网带炉中进行烧结,烧结温度为950℃,烧结时间为1h,通过式网带炉中充有氮气和氢气;烧结完冷却至室温后,混合粉末形成铜基摩擦层覆在支承体外表面进而得到柱塞粗坯,再将柱塞粗坯与模具分离;
步骤四,将初步烧结好的柱塞粗坯放入压力机分体模具中,进一步进行压制,使得铜基摩擦层压实在支承体外表面,其中,压制力为200N/mm2,得到柱塞坯。
步骤五,将压制好的柱塞坯再次放入通过式网带炉中进行回火,烧结气氛与初次烧结相同,烧结温度为1000℃,烧结时间为1h,后冷却至80℃以下取出。
步骤六,将烧结好的柱塞坯进行精密机加工,使得铜基摩擦层厚度为1mm,得到柱塞.
步骤七,将机加工好的柱塞浸入真空吸油机中,使得真空吸油机中的机油填充至铜基摩擦层中的孔隙中,浸油时间为10min。
上述高压柱塞泵用高耐磨自润滑柱塞主要用于使用压力为40~60MPa的高压柱塞泵中,柱塞硬度为125HB左右,结合强度可达50MPa,含油率13%。
实施例2
一种高压柱塞泵用高耐磨自润滑柱塞,包括了铜基摩擦层1和支承体2,所述铜基摩擦层是用镍粉、铁粉、铜粉、锡粉和石墨粉通过粉末冶金的方法复合于圆筒形钢质支承体的外表面,所述铜基摩擦层孔隙中填充机油作为润滑剂。所述圆筒形支承体为45号钢材质。所述铜基摩擦层厚度为2mm。
一种高压柱塞泵用高耐磨自润滑柱塞制备方法,包括以下步骤:
步骤一,准备好钢质圆筒形支承体,先将支承体外表面进行喷砂除锈,然后采用等离子喷涂的方式在支承体外表面形成一层锡青铜薄层。
步骤二,将粒度为180目的镍粉、铁粉、铜粉、锡粉和石墨粉投入滚筒搅拌器中搅拌均匀,其中,镍粉所占比例为10wt%,铁粉55wt%,铜粉15wt%,锡粉10wt%,其余为石墨粉;搅拌时间为2h。
步骤三,将支承体放入外径稍大的圆筒形模具正中间,支撑体外壁与模具内壁之间留有空隙,再将混合粉末填充至两者空隙中,刮除多余混合粉末后一起放至通过式网带炉中进行烧结,烧结温度为1000℃,烧结时间为1.5h,通过式网带炉中充有氮气和氢气;烧结完冷却至室温后,混合粉末形成铜基摩擦层覆在支承体外表面进而得到柱塞粗坯,再将柱塞粗坯与模具分离;
步骤四,将初步烧结好的柱塞粗坯放入压力机分体模具中,进一步进行压制,使得铜基摩擦层压实在支承体外表面,其中,压制力为220N/mm2,得到柱塞坯。
步骤五,将压制好的柱塞坯再次放入通过式网带炉中进行回火,烧结气氛与初次烧结相同,烧结温度为1100℃,烧结时间为1h,后冷却至80℃以下取出。
步骤六,将烧结好的柱塞坯进行精密机加工,使得铜基摩擦层厚度为2mm,得到柱塞。
步骤七,将机加工好的柱塞浸入真空吸油机中,使得真空吸油机中的机油填充至铜基摩擦层中的孔隙中,浸油时间为20min。
上述高压柱塞泵用高耐磨自润滑柱塞主要用于使用压力为60~100MPa的高压柱塞泵中,柱塞硬度为140HB左右,结合强度可达70MPa,含油率15%。
以上所述,仅为本发明较佳的具体实施方式;但本发明的保护范围并不局限于此。任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其改进构思加以等同替换或改变,都应涵盖在本发明的保护范围内。
Claims (10)
1.一种高压柱塞泵用高耐磨自润滑柱塞制备方法,其特征在于,包括以下步骤:
步骤一,准备好钢质圆筒形支承体,先将支承体外表面进行喷砂除锈,然后采用等离子喷涂的方式在支承体外表面形成一层锡青铜薄层;
步骤二,将粒度为40~200目的镍粉、铁粉、铜粉、锡粉和石墨粉投入滚筒搅拌器中搅拌均匀,搅拌时间为1~2h,形成混合粉末;
步骤三,将支承体放入外径稍大的圆筒形模具正中间,支撑体外壁与模具内壁之间留有空隙,再将混合粉末填充至两者空隙中,刮除多余混合粉末后一起放至通过式网带炉中进行烧结,通过式网带炉中充有氮气和氢气;烧结完冷却至室温后,混合粉末形成铜基摩擦层覆在支承体外表面进而得到柱塞粗坯,再将柱塞粗坯与模具分离;
步骤四,将初步烧结好的柱塞粗坯放入压力机分体模具中,进一步进行压制,使得铜基摩擦层压实在支承体外表面,得到柱塞坯;
步骤五,将压制好的柱塞坯再次放入通过式网带炉中进行回火,烧结气氛与初次烧结相同,后冷却至80℃以下取出;
步骤六,将烧结好的柱塞坯进行精密机加工,使得铜基摩擦层厚度为1~3mm,得到柱塞;
步骤七,将机加工好的柱塞浸入真空吸油机中,使得真空吸油机中的机油填充至铜基摩擦层中的孔隙中。
2.根据权利要求1所述的一种高压柱塞泵用高耐磨自润滑柱塞制备方法,其特征在于:所述步骤三中,烧结温度为950~1000℃,烧结时间为1~1.5h。
3.根据权利要求1所述的一种高压柱塞泵用高耐磨自润滑柱塞制备方法,其特征在于:所述步骤四中,压制力为200~220N/mm2。
4.根据权利要求1所述的一种高压柱塞泵用高耐磨自润滑柱塞制备方法,其特征在于:所述步骤五中,烧结温度为950~1300℃,烧结时间为1~1.5h。
5.根据权利要求1所述的一种高压柱塞泵用高耐磨自润滑柱塞制备方法,其特征在于:所述步骤七中,浸油时间为10~30min。
6.根据权利要求1所述的一种高压柱塞泵用高耐磨自润滑柱塞制备方法,其特征在于:以所述铜基摩擦层的总重量为100%计,各组分重量百分含量如下列组分:镍粉:10~15wt%,铁粉:50~60wt%,铜粉:10~30wt%,锡粉:10~15wt%,其余为石墨粉。
7.根据权利要求1-6任意一项所述的高压柱塞泵用高耐磨自润滑柱塞的制备方法的柱塞,其特征在于:包括铜基摩擦层和支承体,所述铜基摩擦层是用镍粉、铁粉、铜粉、锡粉和石墨粉通过粉末冶金的方法复合于圆筒形钢质支承体的外表面,所述铜基摩擦层的孔隙中填充有润滑剂。
8.根据权利要求7所述的一种高压柱塞泵用高耐磨自润滑柱塞,其特征在于:所述润滑剂采用机油。
9.根据权利要求7所述的一种高压柱塞泵用高耐磨自润滑柱塞,其特征在于:所述圆筒形支承体为45号钢材质。
10.根据权利要求7所述的一种高压柱塞泵用高耐磨自润滑柱塞,其特征在于:所述铜基摩擦层厚度为1~3mm。
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