EP2808107A1 - Procédé de fabrication d'un composant MMC - Google Patents

Procédé de fabrication d'un composant MMC Download PDF

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Publication number
EP2808107A1
EP2808107A1 EP13169963.9A EP13169963A EP2808107A1 EP 2808107 A1 EP2808107 A1 EP 2808107A1 EP 13169963 A EP13169963 A EP 13169963A EP 2808107 A1 EP2808107 A1 EP 2808107A1
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EP
European Patent Office
Prior art keywords
particles
tungsten carbide
size
nickel
carbide particles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13169963.9A
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German (de)
English (en)
Inventor
Tomas Berglund
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sandvik Intellectual Property AB
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Sandvik Intellectual Property AB
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Filing date
Publication date
Application filed by Sandvik Intellectual Property AB filed Critical Sandvik Intellectual Property AB
Priority to EP13169963.9A priority Critical patent/EP2808107A1/fr
Publication of EP2808107A1 publication Critical patent/EP2808107A1/fr
Withdrawn legal-status Critical Current

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    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B22F3/15—Hot isostatic pressing
    • 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
    • C22C29/08—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 tungsten carbide
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C22C32/0052—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides
    • 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
    • C22C29/067—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 comprising a particular metallic binder

Definitions

  • the present invention relates to a method for manufacturing a wear resistant component according to the preamble of claim 1.
  • the invention also relates to a wear resistant component according to the preamble of claim 14.
  • abrasion resistant components in mining applications are typically provided with a layer of wear resistant material which consists of hard, wear resistant particles in a ductile steel matrix, a so called Metal Matrix Composite (MMC).
  • MMC Metal Matrix Composite
  • the entire component may be manufactured in a wear resistant material.
  • PTAW Plasma Transferred Arc Welding
  • wear resistant layers that have been applied by PTAW suffer from several drawbacks. For instance, during solidifying of wear resistant layers applied by PTAW, the alloy elements segregate in the molten metal matrix and cause inclusions of e.g. borides and carbides to grow rapidly into large blocks or elongated needle like shapes. As the inclusions grow, they connect with each other and form brittle networks in the ductile metal phase between adjacent tungsten carbide particles, hence reducing the ductility of the wear resistant layer.
  • a further drawback with PTAW layers is that, due to differences in density between tungsten carbide and the metal alloy of the binder phase, the tungsten carbides tend to sink towards the bottom of the applied wear resistant layer. This causes a lower concentration of hard particles in the surface region of the wear resistant layer, thus reducing the hardness at the surface of the wear resistant layer.
  • HIP Hot Isostatic Pressing
  • One typical area of use for Metal Matrix Composites is in applications where the predominant wear mechanism is abrasion, i.e. in which particles slide over a surface and causes wear by scratching the surface. This is for example a common wear mechanism in impellers for transporting slurries of water and sand.
  • a further object of the present invention is to provide a component obtained by the inventive method.
  • a method for manufacturing a wear resistant component comprising the steps:
  • the invention also relates to a component which is obtained by the inventive method.
  • the good resistance to abrasion of the MMC material obtained by the inventive method is due to a combinatory effect of the large size tungsten carbides and the carefully selected size of the ductile alloy particles which constitutes the matrix.
  • the size of the ductile alloy particles have been carefully selected with regard to the size of the tungsten carbide particles. Therefore, when the particles of tungsten carbide and matrix alloy are mixed during manufacturing of the component, the ductile alloy particles are brought to completely surround essentially each individual tungsten carbide particle. In the final component, this in turn has the effect that essentially each large tungsten carbide particle is kept firmly in place in the ductile matrix and that brittle networks of interconnected tungsten particles are avoided. Since the size of the tungsten particles in the component is large, i.e. larger than 250 ⁇ m, the load from a gravel particle which slides over, or impinges the surface of the component is essentially taken by the tungsten particles and the resulting damage on the component is small.
  • sand is meant is a granular material composed of finely divided rock and mineral particles that have a general particle size up to 2 mm.
  • grain is meant unconsolidated rock fragments that have a general particle size above 2 mm typically 2 mm - 64 mm.
  • a capsule 10 is provided.
  • the capsule 10, also referred to as mould or form, is shown in side view in figure 4a and defines at least a portion of the shape or contour of the final component.
  • the capsule 10 is typically manufactured from steel sheets, such as carbon steel sheets that are welded together.
  • the capsule may have any shape.
  • the capsule defines the outer shape of a cylinder and has a circular bottom plate 11, a circumferential outer wall 12 and a cover 13 which is sealed to the outer wall 12 by welding after filling of the form.
  • the capsule 10 may also define a portion of the final component. In that case the capsule 10 is welded to a pre-manufactured component 14, for example a forged or cast component.
  • the capsule 10 is thereby designed such that one of the walls of the capsule, or its bottom, is constituted by a surface of the pre-manufactured component 14, see figure 4b .
  • This has the advantage that pre-manufactured components may be provided with a layer of wear resistant material.
  • the powder mixture consists of a powder of tungsten carbide particles and a powder of a nickel based alloy or cobalt based alloy.
  • the tungsten carbide particles may be WC or W 2 C or a mixture of WC and W 2 C.
  • the tungsten carbide particles may be of spherical or facetted shape.
  • the mean size of the tungsten particles is at least 250 ⁇ m, i.e. ⁇ 250 ⁇ m.
  • the large tungsten carbide particles provide wear resistance by absorbing the load from gravel that impinges or slides over the surface of the component. It is believed that tungsten particle sizes of at least 250 ⁇ m provides very good resistance to abrasive wear from gravel slurries or sand slurries, even under conditions that cause the abrasive/erosive particles to wear the surface with high normal force.
  • the wear resistance to gravel size particles increases with increasing size of the tungsten particles. However, when the size of the tungsten particles exceed 650 ⁇ m the resulting mean distance between the tungsten particles becomes very large which in turn may result in that the ductile matrix phase is eroded, so called wash-out.
  • the mean size of the tungsten particles is 250 - 450 ⁇ m. It is believed that these sizes provides good resistance to slurries containing a predominant fraction of sand sized particles. According to a second embodiment, the mean size of the tungsten particles is 450 - 650 ⁇ m. It is believed that these sizes provides good resistance to slurries containing a predominant fraction of gravel sized particles.
  • the powder of the nickel based or cobalt based alloy constitutes the ductile phase in the final consolidated component.
  • cobalt-based or “nickel-based” is meant that the main constituent in the alloy is nickel respectively cobalt.
  • Nickel based alloys are generally strong and ductile and therefore very suitable as matrix material in abrasive resistant applications.
  • a further advantage with nickel based alloys is that carbon has very low solubility in nickel, which constitutes the main element of the alloy. Low solubility of carbon is an important characteristic in the matrix material in order to avoid dissolving of the tungsten particles.
  • Nickel is further inexpensive in comparison to cobalt, another conventional matrix material.
  • Cobalt based alloys are known to provide good wettability towards the tungsten carbides which improves bonding.
  • a cobalt based matrix provides better wear resistance compared to other types of matrix material.
  • the nickel based or cobalt based alloy should preferably contain chromium in an amount of 3 - 35wt% or 3-20 wt%, preferably 12-20 wt%.
  • Chromium forms together with carbon and iron, small metal rich carbides, for example M 23 C 6 and M 7 C 3 that are precipitated in the ductile nickel based alloy matrix.
  • the precipitated carbides strengthen the matrix by blocking dislocations from propagating. Since the precipitated particles also are hard, they also increase the wear resistance of the matrix.
  • chromium is a strong carbide former, high amount of chromium could lead to decomposition of the large tungsten carbide particles.
  • the powder of the nickel based alloy may have the following composition in weight % (wt%): C: 0 - 1.0; Cr: 3 - 20; Si: 2.5 - 4.5; B: 1.25 - 3.0; Fe: 1.0 - 4.5; the balance Ni and unavoidable impurities.
  • the powder of cobalt based alloy may have the following composition in weight % (wt%): %): C: 0 - 3.0; Cr: 3 - 35; W: 0-20; Mo: 0-15; Si: 0.3 - 1.5; Fe: 1.0 - 10; the balance Co and unavoidable impurities.
  • the nickel based or cobalt based alloy particles have a substantially spherical shape, alternatively a deformed spherical shape.
  • the size of the nickel based or cobalt based alloy particles is ⁇ 1/ 5 of the size of the tungsten carbide particles in the powder mixture.
  • the size of the alloy particles is 50 ⁇ m if the mean size of the tungsten carbide particles is 250 ⁇ m and the size of the alloy particles is 1/5 of the size of the tungsten carbide particles.
  • the tungsten particles may not be sufficiently embedded in alloy powder and thus form brittle networks which reduce wear resistance and toughness of the material. Therefore the size of the alloy particles is set to maximum 1/5 of the size of the tungsten particles.
  • the minimum size of the alloy particles is preferably limited to 10 ⁇ m since powder of smaller size is difficult to handle.
  • the size of the nickel based or cobalt based alloy particles is 1/10 - 1/5 or 1/8 - 1/6 of the size of the tungsten carbide particles in the powder mixture.
  • the size of the tungsten carbide particles is 250 -450 ⁇ m and the size of the alloy particles is 1/20 - 1/10 of the size of the tungsten carbide particles.
  • a material manufacture of a powder of this size distribution is believed to have very good resistance to wear from slurries containing predominantly sand.
  • the size of the tungsten carbide particles is 450 -650 ⁇ m and the size of the alloy particles is 1/30 - 1/20 of the size of the tungsten carbide particles.
  • a material manufacture of a powder of this size distribution is believed to have very good resistance to wear from slurries containing predominantly gravel.
  • the specific relationship between the particle sizes of the nickel or cobalt based alloy and the tungsten carbide particles ensures that the alloy powder completely surrounds the tungsten particles. Thereby it is ensured that the tungsten particles are firmly integrated in the matrix of the component. It is further avoided that brittle networks of interconnected tungsten carbide particles are formed. In practice, such network may have a negative effect on toughness and the wear resistance since the interconnected tungsten carbide particles easily could serve as paths where cracks easily propagate and thereby lead to failure of the component. As a result of crack networks, the carbides could then more easily be torned away or knocked out from the surface of the component by gravel
  • the size of the tungsten carbide particles and the size of the nickel based and cobalt based alloy particles may be determined with laser diffraction, i.e. analysis of the "halo" of diffracted light produced when a laser beam passes through a dispersion of particles in air or in liquid.
  • the size of the nickel based or cobalt based alloy particles is measured as "d90" which means that 90% of the particles have a size which is smaller than a specific value.
  • the size of the tungsten carbide particles is determined as the mean size of a volume of particles.
  • the powder of tungsten carbide particles is mixed with the powder of nickel or cobalt based alloy particles in a ratio of 30 -70 vol% of tungsten carbide powder and the remainder nickel based alloy powder.
  • the exact volume ratio between the tungsten carbide powder and the matrix forming alloy powder in the inventive powder mixture is determined by the wear condition in the application that the consolidated component is intended for. However, with regard to the tungsten carbide powder, the lowest acceptable amount is 30 vol% in order to achieve a significant resistance to abrasion. The amount of tungsten carbide powder should not exceed 70 vol% since the HIP:ed component then may become too brittle. It is further difficult to blend or mix amounts of tungsten carbide powder exceeding 70 vol% with the alloy particles forming the matrix to a degree where essentially all the tungsten carbide particles are completely embedded in the alloy powder.
  • the volume ratio may for example be 40 vol% tungsten carbide powder and 60 vol% alloy powder, or 50 vol% tungsten carbide powder and 50 vol% of alloy powder, or 45 vol% tungsten carbide powder and 55 vol% of alloy powder.
  • tungsten carbide powder and the alloy powder forming the matrix are blended into a powder mixture.
  • Blending is preferably performed in V-type mixer.
  • the blending step ensures that the tungsten carbide particles are distributed uniformly in the volume of inventive powder mixture and that essentially all tungsten carbide particles are individually embedded in alloy powder.
  • the powder mixture 16 is poured into the capsule 10 that defines the shape of the component.
  • the capsule is thereafter sealed, for example by welding the cover 13 onto the circumferential wall 12.
  • a vacuum may be applied to the powder mixture, for example by the use of a vacuum pump. The vacuum removes the air from the powder mixture. It is important to remove the air from the powder mixture since air contains argon, which has a negative effect on ductility of the resulting material.
  • the filled capsule 10 is subjected to Hot Isostatic Pressing (HIP) at a predetermined temperature, a predetermined isostatic pressure and for a predetermined time so that the particles of the alloy powder forming the matrix bond metallurgical to each other.
  • HIP Hot Isostatic Pressing
  • the powder containing capsule 10 is thereby placed in a heatable pressure chamber 17, normally referred to as a Hot Isostatic Pressing-chamber (HIP-chamber).
  • HIP-chamber Hot Isostatic Pressing-chamber
  • the heating chamber is pressurized with gas, e.g. argon gas, to an isostatic pressure in excess of 500 bar. Typically the isostatic pressure is 900 - 1200 bar.
  • the chamber is heated to a temperature which is below the melting point of nickel or cobalt based alloy powder. The closer the temperature is to the melting point, the higher is the risk for the formation of melted phase and unwanted streaks of brittle carbide- and boride networks. Therefore, the temperature should be as low as possible in the furnace during HIP:ing. However, at low temperatures the diffusion process slows down and the material will contain residual porosity and the metallurgical bond between the particles becomes weak. Therefore, the temperature is 900 - 1150°C, preferably 1000 - 1150°C.
  • the form is held in the heating chamber at the predetermined pressure and the predetermined temperature for a predetermined time period.
  • the diffusion processes that take place between the powder particles during HIPP:ing are time dependent so long times are preferred.
  • the form should be HIP:ed for a time period of 0.5 - 3 hours, preferably 1 - 2 hours, most preferred 1 hour.
  • the capsule is stripped from the consolidated component.
  • the form may be left on the component.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)
EP13169963.9A 2013-05-31 2013-05-31 Procédé de fabrication d'un composant MMC Withdrawn EP2808107A1 (fr)

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Application Number Priority Date Filing Date Title
EP13169963.9A EP2808107A1 (fr) 2013-05-31 2013-05-31 Procédé de fabrication d'un composant MMC

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113732285A (zh) * 2021-11-05 2021-12-03 西安赛隆金属材料有限责任公司 一种铁镍钴基粉末合金及提高其延伸率的方法
WO2023052778A1 (fr) 2021-09-29 2023-04-06 Zeal Innovation Ltd Dispositifs de sécurité

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2109417A (en) * 1981-11-16 1983-06-02 Castolin Sa Flame-spraying material
US20100108399A1 (en) * 2008-10-30 2010-05-06 Eason Jimmy W Carburized monotungsten and ditungsten carbide eutectic particles, materials and earth-boring tools including such particles, and methods of forming such particles, materials, and tools
US20100116557A1 (en) * 2008-05-15 2010-05-13 Smith International, Inc. Matrix bit bodies with multiple matrix materials
US20100276208A1 (en) * 2009-04-29 2010-11-04 Jiinjen Albert Sue High thermal conductivity hardfacing for drilling applications
US20110031028A1 (en) * 2009-08-06 2011-02-10 National Oilwell Varco, L.P. Hard Composite with Deformable Constituent and Method of Applying to Earth-Engaging Tool

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2109417A (en) * 1981-11-16 1983-06-02 Castolin Sa Flame-spraying material
US20100116557A1 (en) * 2008-05-15 2010-05-13 Smith International, Inc. Matrix bit bodies with multiple matrix materials
US20100108399A1 (en) * 2008-10-30 2010-05-06 Eason Jimmy W Carburized monotungsten and ditungsten carbide eutectic particles, materials and earth-boring tools including such particles, and methods of forming such particles, materials, and tools
US20100276208A1 (en) * 2009-04-29 2010-11-04 Jiinjen Albert Sue High thermal conductivity hardfacing for drilling applications
US20110031028A1 (en) * 2009-08-06 2011-02-10 National Oilwell Varco, L.P. Hard Composite with Deformable Constituent and Method of Applying to Earth-Engaging Tool

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023052778A1 (fr) 2021-09-29 2023-04-06 Zeal Innovation Ltd Dispositifs de sécurité
DE202022002833U1 (de) 2021-09-29 2023-09-19 Zeal Innovation Ltd Sicherheitsvorrrichtungen
CN113732285A (zh) * 2021-11-05 2021-12-03 西安赛隆金属材料有限责任公司 一种铁镍钴基粉末合金及提高其延伸率的方法

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