EP2956561A1 - Metal matrix composite useful as wear parts for cement and mining industries - Google Patents
Metal matrix composite useful as wear parts for cement and mining industriesInfo
- Publication number
- EP2956561A1 EP2956561A1 EP14707106.2A EP14707106A EP2956561A1 EP 2956561 A1 EP2956561 A1 EP 2956561A1 EP 14707106 A EP14707106 A EP 14707106A EP 2956561 A1 EP2956561 A1 EP 2956561A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- metal matrix
- ceramic
- matrix composite
- tic
- cast metal
- 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.)
- Granted
Links
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
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0207—Using a mixture of prealloyed powders or a master alloy
- C22C33/0228—Using a mixture of prealloyed powders or a master alloy comprising other non-metallic compounds or more than 5% of graphite
-
- 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
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
-
- 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
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
- C22C1/1057—Reactive infiltration
Definitions
- the present invention generally relates to cast metal matrix composites, uses thereof and methods for the preparation thereof.
- Wear parts are used in many industries such as cement and mining industries.
- the metal matrix composites used as wear parts have to comply with several requirements in order to be efficient.
- the wear parts are usually implemented within mining equipment intended to crush and grind the solid material. Thus, they have to show a good resistance to the impacts and the abrasion to which they are subjected during their use.
- Ductile materials show improved resistance to impact but low resistance to abrasion whereas hard abrasion-resistant materials provide a satisfying resistance to abrasion but low resistance to violent impacts.
- the wear parts are consumable materials involving their frequent replacements. It is essential that the replacements of these wear parts be spaced out, easy and cost less. The production costs of the wear parts have to be low for being implemented in the industry.
- the present invention aims to provide a reinforced cast metal matrix composite useful as wear parts for cement and mining industries.
- the present invention also intends to provide wear parts showing an extended life service with high production rates while having low production costs.
- the cast metal matrix composite according to the present invention comprises two distinct parts namely: - One or more ceramic cakes comprising: AI2O3, ZrO2 , ferrous metal and TiC,
- the ceramic cakes correspond to the hard material of the cast metal matrix composite.
- the ceramic cakes are preformed before being included within the metal matrix.
- These ceramic cakes show a high hardness due to their composition comprising, in particular, a mixture of TiC and inorganic compounds: AI2O3 and ZrO 2 .
- the metal matrix includes a ferrous metal and TiC.
- the presence of TiC allows reinforcing the matrix of metal. Indeed, the inventors have noted that the reinforcement of the metal matrix with TiC allows obtaining a better resistance of the ceramic cakes within the metal matrix. It means that the ceramic cakes are maintained more strongly within the metal matrix and thus are more hardly removed from it when submitted to the use conditions. Indeed, the presence of TiC within the metal matrix increases its hardness, but does not affect the fracture toughness. The obtained material is thus more wear resistant without increasing the risk for cracking. Furthermore, the inventors surprisingly found out that the insertion of the ceramic compounds (AI2O3 and Zr0 2 ) is improved when the metal matrix also comprises TiC.
- the metal matrix composite according to the present invention is prepared by a casting process.
- a casting process offers several advantages since it is economical and easy to implement.
- the formation of TiC within the ceramic cakes occurs during the casting process namely during the pouring step of the metal matrix
- the addition of the melt metal matrix upon the ceramic cakes leads to the formation of TiC within the ceramic cakes.
- titanium and carbon are very reactive components and lead to the production of TiC when they are mixed at temperatures above about 1 100°C.
- the particles of TiC obtained show a diameter/size of inferior or equal to about 30 microns. Furthermore, these particles are homogenously distributed within the metal matrix.
- the formation of the TiC particles leads to an increase in strength, strain and hardness of the material obtained, which in turn allows improving its service lifespan and its wear resistance.
- Fig. 1 shows a ceramic cake having a honeycomb shape.
- Fig. 2 shows a detail of the ceramic cake having a honeycomb shape before pouring the metal matrix.
- Fig. 3 shows a view of a cast metal matrix composite according to the present invention wherein ceramic cakes are included within a metal matrix.
- Fig. 4 shows portions comprising ceramic cake and a metal matrix in a suitable shape, namely adapted to be inserted within a further metal layer.
- the present invention proposes a cast metal matrix composite which comprises ceramic cakes included within a metal matrix.
- this cast metal matrix composite is reinforced by the simultaneous presence of TiC in the ceramic cakes and the metal matrix.
- the cast metal matrix according to the present invention comprises:
- one or more ceramic cakes comprising: AI2O3, ZrO2 , ferrous metal and TiC and
- TiC which is present within the ceramic cakes and the metal matrix is obtained through the following in situ reaction: FeTi+C which converts to Fe+TiC. This reaction is obtained by contacting the reagent materials at high temperatures, namely at temperatures over about 1 100°C.
- FeTi+C which converts to Fe+TiC. This reaction is obtained by contacting the reagent materials at high temperatures, namely at temperatures over about 1 100°C.
- a binder is used, within the ceramic cakes, in order to aggregate the grains of ceramic.
- the binder used in the ceramic cake may be preferably an inorganic binder.
- the binder may be selected from the group comprising sodium silicate, colloidal silicate or a mixture thereof.
- the use of the colloidal silicate reduces the hygroscopic properties of the material obtained and thus avoids the increase of the moisture within the material. Indeed, this is due to the structure of the colloidal silicate which allows binding the sites which could be occupied by the water molecules. Contrary to other binders, the colloidal silicates limit the absorption of water (for example from the ambient air) by the ceramic cakes. Thus, the strength of the ceramic cakes does not decrease which prevents the formation of cracks.
- the known processes require the use of the ceramic cakes as fast as possible. Such processes do not allow the preformation of large quantities of ceramic cakes since they cannot be stored during a sufficiently long period.
- the use of colloidal silicate as a binder represents a preferred embodiment of the present invention with significant advantages since a large amount of ceramic cakes can be prepared well before the actual casting of the metal matrix, stored during extended periods and used as needed.
- the ceramic cake before the pouring step comprises from 3 to 6 wt% and preferably from 4 to 5 wt% of binder compared to the total weight of the ceramic cake.
- the quantity of graphite is comprised between 0,2 and 4wt%, preferably from 0,5wt% to 3wt% and preferably from 0,875wt% to 2,625wt% compared to the total weight of the ceramic cake.
- the ceramic cake comprises 1 to 20 wt% of FeTi and preferably from 5 to 15wt% compared to the total weight of the ceramic cake.
- the ceramic cake generally also comprises from 30 to 60 wt% and preferably from 40 to 55 wt% of AI2O3 compared to the total weight of the ceramic cake.
- the quantity of ZrO 2 is comprised between 20 and 40 wt% and in particular between 25 and 35 wt% compared to the total weight of the ceramic cake.
- the ceramic cake comprises from 30 to 60wt% of AI 2 O 3 , from 20 to 40wt% of ZrO 2 , from 0,2 to 4wt% of graphite, from 1 to 20wt% of FeTi and from 3 to 6wt% of binder compared to the total weight of ceramic cake before the pouring step.
- the ceramic cake comprises from 2 to 10vol% of TiC and preferably from 4 to 8vol% of TiC.
- the ceramic cakes may have any shape allowing the filling of the metal in the gaps between the ceramic particles, in particular the ceramic cakes may have a honeycomb shape (1 ) as shown in Fig .1 . Indeed, it has been noted that such a shape is particularly suitable for the use according to the present invention. In fact, when casting the metal matrix, the metal can easily and quickly infiltrate each cavity of the ceramic cake (1 ), whereas without such shape, the metal matrix could solidify before entirely filling the cavities of the ceramic cake. This shape therefore allows a better infiltration of the metal matrix.
- Fig.2 shows a detailed view of this honeycomb (preform) ceramic cake (1 ) before pouring the metal matrix, which thus comprises AI2O3, ZrO2 (corresponding to grains of ceramic (2)), FeTi (3) and graphite (4).
- the cast metal matrix composite according to the invention may comprise a plurality of ceramic cakes, wherein the ceramic cakes have a honeycomb shape.
- the metal matrix it comprises a ferrous metal.
- Ferrous metals can be defined as metals which comprise a largest part of metal(s) comprising iron (Fe), for example: steels, cast irons and their alloys with other metals.
- the ferrous metals can be selected from: High Chromium Iron (like for example ASTM A532 Class 2 type E), Chromium steel (like for example DIN 1 .2601 ), Ni hard metals (like for example ASTM A532 Class 1 type D) or low alloy steel (like for example DIN 1 .2356) and combinations thereof.
- the metal matrix includes from 50 to 90 wt% and preferably from 60 to 85 wt% of ferrous metal compared to the total weight of the metal matrix.
- the metal matrix also includes TiC.
- TiC is comprised from 0,1 to 10 vol%, and in particular from 2 to 6 vol% compared to the total volume of the metal matrix.
- the metal matrix may comprise from 50 to 90wt% of ferrous metal compared to the total weight of the metal matrix and from 0,1 to 10vol% of TiC and in particular from 2 to 6 vol% of TiC compared to the total volume of the metal matrix.
- the cast metal matrix composite comprises from 2 to 10 vol% of TiC, preferably from 4 to 8 vol% TiC, and preferably about 6 vol% TiC with respect to the total volume of metal in the ceramic cake after pouring the metal matrix. It has been identified that wear resistance of ferrous metal casting will be improved by increasing the volume% of TiC up to 6vol%. In fact, a wear resistance peak has been observed at about 6vol% whereas TiC is still homogeneously distributed in ferrous matrix.
- Fig.3 shows a cross-section of a cast metal matrix composite (5) according to one embodiment of the present invention.
- the ceramic cakes (1 ) are placed in a resin-type mold.
- a metal matrix (6) has been poured within the ceramic cakes in order to fill the resin-type mold.
- a cast metal matrix composite (5) comprising ceramic cakes (1 ) embedded within a metal matrix (6).
- the cast metal matrix composite can also comprise an additional metal, in particular a ductile metal.
- This metal can be selected among the ductile irons.
- such cast metal matrix composite would include one ceramic cake and two metals.
- the ductile metal improves the toughness of the cast metal matrix composite material and allows rendering the material more resistant to shocks and breaking.
- the cast metal matrix composite according to the present invention can be used as wear parts for cement and mining industries.
- the present invention also concerns an article comprising the cast metal matrix composite according to the present invention such as: wear parts.
- the wear parts comprising the cast metal matrix composite can be used in general in plants for grinding, crushing and conveying various abrasive materials; in mining and construction equipments such as bucket wheel excavators, dragline excavators, high capacity haulage trucks, and crushing/milling machines; in industries such as cement factories, mines, metallurgy or electricity generating stations.
- the article comprising the cast metal matrix composite according to the present invention may also be raw mill, coal mill, grinding mill castings, roller and table segments (or liners) for raw, coal, grinding mills, or crushers or kiln cooler parts.
- the method for producing the cast metal matrix composite includes two main steps.
- the first one (step (a)) concerns the preparation of the ceramic cakes preforms and the second one (step (b)) relates to the casting of the metal matrix upon the ceramic cakes.
- the second step (b) corresponds to a casting step which is convenient to implement and low-cost.
- the preparation of the preformed ceramic cakes includes the steps of: - mixing AI2O3, ZrO2, FeTi, graphite and a binder, - filling the mixture obtained in preform molds,
- the preform molds are silicone core boxes. Indeed, such kinds of molds, which are very flexible, allow easily removing the ceramic cakes.
- the preform molds can be in honeycomb shape in order to facilitate the infiltration of the metal matrix when casting.
- the heating step of the mixture may be performed with a microwave oven, an infrared oven or a conventional oven, such as a gas or electrical convection oven.
- the ceramic cakes After being cooled at about room temperature (for example below 40°C), the ceramic cakes are ready to be subjected to the casting step (or stored until casting is performed).
- the method provides the additional advantage that the ceramic cakes can be prepared well before the casting of the metal matrix.
- the ceramic cakes can be preformed and stored during one week before being used for the preparation of the cast metal matrix composite.
- a large quantity of ceramic cakes can be prepared since they are not subjected to the constraint of being immediately used in the casting process.
- the second step (b) of the process concerns casting the ceramic cakes into a composite.
- a metal matrix should be casted/poured upon the ceramic cakes in order to cover and to infiltrate them.
- the ceramic cakes may be placed e.g. in resin-type molds, such as at the upper surface or the side surface of this resin- type mold.
- the density of the ceramic cake is lower than the density of the metal matrix.
- the ceramic cakes are forced to float.
- the ceramic cakes are heated up by hot air convection which allows an easy penetration of the metal matrix.
- Any appropriate resin-type mold can be used for the preparation of the cast metal matrix composite, such as for example ALpHASET ® , furan, sodium silicate or other sand molds.
- the ceramic cakes can be screwed to the resin type mold with steel screws or otherwise affixed thereto.
- the resin-type mold is closed before pouring the metal matrix.
- the metal matrix is prepared by mixing and melting (at least) ferrous metal with ferrotitanium and graphite. This step can be performed in a furnace such as an induction furnace.
- the ferrotitanium and the carbon should be preferably added within the mixture after the ferrous metal.
- the ferrotitanium can be added either into the furnace, in the ladle or directly in the resin-type mold.
- the advantage to add the ferrotitanium within the furnace is the possibility to use less expensive ferrotitanium which comprises only 30-50 wt% of Ti.
- the carbon or graphite it is preferable to add it directly in the furnace.
- the carbon is added in the furnace and the ferrotitanium is added in the ladle.
- the pouring step should be performed at a temperature which is 250 to 300°C above the liquidus of the metal.
- the metal matrix should be poured in the resin-type mold in order to cover and to infiltrate the ceramic cakes and to cover the walls of the resin-type mold.
- Additional fettling operations identical to the conventional ones may be implemented.
- the cast metal matrix composite may for example be subjected to an additional heat treatment.
- a further metal can be added to the cast metal matrix composite obtained through the above-mentioned method for improving its resistance to shocks.
- This metal should be selected among metals more ductile than that used in step (b), for example ductile irons.
- the method according to the present invention may further comprise an additional step (c) which involves:
- step (b) placing one or several portion(s) of the cast metal matrix composite obtained from step (b) in a further resin-type mold
- Fig .4 shows portions (7) of cast metal matrix composite. These portions (7) are produced in a shape suitable for being included in another metal. As it is shown, these portions comprise the ceramic cakes (1 ) having a honeycomb shape which are filled with a metal matrix (6).
- these portions obtained may be placed in a further resin-type mold for being subjected to a (further) casting step.
- this resin-type mold should be heat resistant and could for example comprise sodium silicate.
- the portions may be heated up before the pouring step.
- the additional metal matrix is poured in the resin-type mold upon the portions.
- the portions are included within the ductile metal, thereby obtaining a cast metal matrix composite comprising ceramic cakes, a hard wear metal matrix and a ductile shock resistant metal.
- the ductile metal constitutes the carrier of the portions of cast metal matrix composites. Fettling operations may be further implemented and a heat treatment may be applied.
- Fig.5 A and B illustrate this specific embodiment.
- Fig.5-A shows this embodiment wherein the portions are visible by transparency within the (preferably ductile) metal whereas in Fig 5-B the parts of the portions which are included within the (preferably ductile) metal are not shown.
- Fig.5 A and B show portions
- the composite obtained according to this embodiment (9) comprises both a wear resistant metal matrix composite (7) on the wearing side and shock resistant ductile iron (8) at the carrier side.
- the portions (7) are preferably spaced in such a way that the cast ductile iron (8) can be infiltrated between these portions.
- compositions of cast metal matrix [0067] The following examples of metal matrixes have been produced by a method according to the present invention.
- All the cast metal matrix composites according to the present invention show a very good wear resistance.
- the presence of TiC in both ceramic cakes and metal matrix allows increasing the hardness of the cast metal matrix composites without affecting its fracture toughness.
- the ceramic compounds are homogeneously distributed within the metal matrix.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
LU92152A LU92152B1 (en) | 2013-02-18 | 2013-02-18 | Metal matrix composite useful as wear parts for cement and mining industries |
PCT/EP2014/052837 WO2014125034A1 (en) | 2013-02-18 | 2014-02-13 | Metal matrix composite useful as wear parts for cement and mining industries |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2956561A1 true EP2956561A1 (en) | 2015-12-23 |
EP2956561B1 EP2956561B1 (en) | 2019-11-27 |
Family
ID=47739436
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP14707106.2A Active EP2956561B1 (en) | 2013-02-18 | 2014-02-13 | Metal matrix composite useful as wear parts for cement and mining industries |
Country Status (6)
Country | Link |
---|---|
EP (1) | EP2956561B1 (en) |
CN (1) | CN105026584B (en) |
AU (1) | AU2014217875B2 (en) |
LU (1) | LU92152B1 (en) |
WO (1) | WO2014125034A1 (en) |
ZA (1) | ZA201505284B (en) |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN108057874B (en) * | 2016-10-31 | 2023-03-17 | 张志国 | Three-dimensional network ceramic framework reinforcement metal-based composite refractory material and preparation method thereof |
BE1027444B1 (en) | 2020-02-11 | 2021-02-10 | Magotteaux Int | COMPOSITE WEAR PART |
EP3915684A1 (en) * | 2020-05-29 | 2021-12-01 | Magotteaux International SA | Composite wear part |
EP3915699A1 (en) * | 2020-05-29 | 2021-12-01 | Magotteaux International SA | Ceramic-metal composite wear part |
CN112872351B (en) * | 2021-01-13 | 2023-07-14 | 太原理工大学 | Preparation method of hybrid synergistic reinforced iron-based wear-resistant material |
CN112872330B (en) * | 2021-01-13 | 2022-06-28 | 太原理工大学 | Preparation method of space grid-shaped ceramic/metal wear-resistant material |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA2468352C (en) * | 2001-12-04 | 2010-06-15 | Claude Poncin | Cast parts with enhanced wear resistance |
US8147980B2 (en) * | 2006-11-01 | 2012-04-03 | Aia Engineering, Ltd. | Wear-resistant metal matrix ceramic composite parts and methods of manufacturing thereof |
BE1018128A3 (en) * | 2008-09-19 | 2010-05-04 | Magotteaux Int | GRINDING CONE FOR COMPRESSION CRUSHER. |
BE1018130A3 (en) * | 2008-09-19 | 2010-05-04 | Magotteaux Int | HIERARCHICAL COMPOSITE MATERIAL. |
-
2013
- 2013-02-18 LU LU92152A patent/LU92152B1/en active
-
2014
- 2014-02-13 EP EP14707106.2A patent/EP2956561B1/en active Active
- 2014-02-13 WO PCT/EP2014/052837 patent/WO2014125034A1/en active Application Filing
- 2014-02-13 AU AU2014217875A patent/AU2014217875B2/en not_active Ceased
- 2014-02-13 CN CN201480008225.XA patent/CN105026584B/en active Active
-
2015
- 2015-07-22 ZA ZA2015/05284A patent/ZA201505284B/en unknown
Non-Patent Citations (1)
Title |
---|
See references of WO2014125034A1 * |
Also Published As
Publication number | Publication date |
---|---|
WO2014125034A1 (en) | 2014-08-21 |
AU2014217875A1 (en) | 2015-08-06 |
LU92152B1 (en) | 2014-08-19 |
ZA201505284B (en) | 2016-05-25 |
EP2956561B1 (en) | 2019-11-27 |
CN105026584A (en) | 2015-11-04 |
AU2014217875B2 (en) | 2019-06-20 |
CN105026584B (en) | 2017-11-28 |
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