EP3915684A1 - Pièce d'usure composite - Google Patents

Pièce d'usure composite Download PDF

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Publication number
EP3915684A1
EP3915684A1 EP20177458.5A EP20177458A EP3915684A1 EP 3915684 A1 EP3915684 A1 EP 3915684A1 EP 20177458 A EP20177458 A EP 20177458A EP 3915684 A1 EP3915684 A1 EP 3915684A1
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EP
European Patent Office
Prior art keywords
alumina
zirconia
alloy
metal matrix
inserts
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.)
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EP20177458.5A
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German (de)
English (en)
French (fr)
Inventor
Guy Berton
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Magotteaux International SA
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Magotteaux International SA
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Application filed by Magotteaux International SA filed Critical Magotteaux International SA
Priority to EP20177458.5A priority Critical patent/EP3915684A1/fr
Priority to US18/000,245 priority patent/US20230201920A1/en
Priority to CA3185012A priority patent/CA3185012A1/en
Priority to EP21713434.5A priority patent/EP4157538A1/fr
Priority to AU2021278584A priority patent/AU2021278584A1/en
Priority to BR112022023593A priority patent/BR112022023593A2/pt
Priority to PE2022002695A priority patent/PE20231236A1/es
Priority to CN202180038714.XA priority patent/CN115867390A/zh
Priority to PCT/EP2021/057816 priority patent/WO2021239295A1/fr
Publication of EP3915684A1 publication Critical patent/EP3915684A1/fr
Priority to ZA2022/12082A priority patent/ZA202212082B/en
Priority to CL2022003167A priority patent/CL2022003167A1/es
Withdrawn legal-status Critical Current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
    • B22F3/004—Filling molds with powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C13/00—Disintegrating by mills having rotary beater elements ; Hammer mills
    • B02C13/26—Details
    • B02C13/28—Shape or construction of beater elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C2/00—Crushing or disintegrating by gyratory or cone crushers
    • B02C2/005—Lining
    • 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
    • B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
    • 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
    • B22D19/06—Casting in, on, or around objects which form part of the product for manufacturing or repairing tools
    • 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
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/12—Metallic powder containing non-metallic particles
    • 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
    • B22F3/02—Compacting only
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/008—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression characterised by the composition
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0475—Impregnated alloys
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
    • 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
    • C22C1/1005—Pretreatment of the non-metallic additives
    • C22C1/1015—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform
    • 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
    • C22C1/1047—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
    • 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
    • C22C1/1068—Making hard metals based on borides, carbides, nitrides, oxides or silicides
    • 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
    • C22C33/0242—Making ferrous alloys by powder metallurgy using the impregnating technique
    • 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
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0292—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with more than 5% preformed carbides, nitrides or borides
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C2210/00—Codes relating to different types of disintegrating devices
    • B02C2210/02—Features for generally used wear parts on beaters, knives, rollers, anvils, linings and the like
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B22F2007/066—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using impregnation
    • 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
    • B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
    • B22F2302/25—Oxide
    • 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
    • B22F2303/00—Functional details of metal or compound in the powder or product
    • B22F2303/35—Molten metal infiltrating a metal preform
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • the present invention relates to a wear part produced in a foundry. It relates more particularly to a hierarchical wear part comprising a reinforced part on its most stressed side.
  • the reinforced part is obtained by placing a reinforcement consisting of an aggregate of millimeter grains with millimeter interstices in a mold in preparation for the casting of the wearing part.
  • the reinforcement also includes centimetric ceramic inserts previously manufactured according to a predefined geometry. The inserts comprise micrometric ceramic particles bound in a first metal matrix and the millimeter interstices of the reinforcement are infiltrated during casting by a second metal matrix. The first metal matrix is independent of the second metal matrix.
  • the present invention also provides a method for obtaining said wearing part with its reinforcing structure.
  • the ore extraction and fragmentation facilities and in particular the grinding and crushing equipment are subject to numerous constraints in terms of impact resistance and abrasion resistance.
  • wearing parts include ejectors and anvils of vertical-axis crushers, hammers and beaters of horizontal-axis crushers, cones for crushers, tables and rollers. Vertical mills, armor plates and lifters for ball or bar mills.
  • pumps for tar sands or drilling machines we will cite, among others, pumps for tar sands or drilling machines, mining pumps and dredging teeth.
  • EP0575685A1 (Sulzer, 1996 ) describes a molded part with wear surfaces reinforced by porous ceramic bodies embedded in a metallic phase, each ceramic body having a structure in the form of a porous three-dimensional network.
  • WO9815373A1 discloses a composite wear part produced in a foundry. It comprises a metal matrix with reinforcements produced by a three-dimensional structure of agglomerated grains comprising a homogeneous phase of 20 to 80% of Al 2 O 3 and 80 to 20% of ZrO 2 .
  • WO2016008967A1 discloses sintered ceramic grains comprising from 3 to 55% by weight of alumina and 40 to 95% by weight of zirconia associated with inorganic components such as rare metal oxides or alkaline earth metal oxides.
  • the present invention aims to overcome the drawbacks of the state of the art and in particular the difficulty of obtaining reinforcement zones comprising a very high concentration of ceramic particles. It also aims to integrate areas with a high concentration of ceramic particles within a three-dimensional structure of aggregated millimeter grains mainly based on alumina-zirconia comprising millimeter interstices which can be infiltrated by the casting ferrous alloy.
  • the millimetric grain reinforcement structure simultaneously makes it possible to ensure the positioning of prefabricated inserts of defined geometry and concentrated in ceramic particles such as carbides, nitrides, borides or intermetallic elements in the mold of the wearing part.
  • the inserts have a first metal matrix as a binder of the ceramic particles independent of the casting alloy constituting the second metal matrix.
  • the present invention discloses a hierarchical wear part comprising a reinforced part comprising alumina, zirconia or an alumina-zirconia alloy, said reinforced part also comprising centimetric inserts of predefined geometry, said inserts comprising micrometric particles of metal carbides, nitrides, borides or intermetallic compounds linked by a first metal matrix, said inserts being inserted into a reinforcing structure infiltrated by a second metal matrix, the reinforcing structure comprising a periodic alternation of high and low millimeter zones concentration of micrometric particles of alumina, zirconia or an alumina-zirconia alloy, the second metal matrix being different from the first metal matrix.
  • the inserts of predefined geometry manufactured prior to the casting of said wearing part are produced by powder metallurgy.
  • the present invention also discloses the invention in the form of an impactor, an anvil, a cone or a grinding roller.
  • the present invention discloses a wear part with increased resistance to wear produced in a conventional foundry. It relates more particularly to a wear part comprising a reinforced part according to a predefined geometry with ceramic inserts (cylinders, polygons, cones, etc.) at the scale of a few centimeters previously manufactured and inserted into an infiltrated three-dimensional structure. made up of agglomerated millimeter grains and forming a periodic alternation of millimeter grains and interstices.
  • the grains used to manufacture the three-dimensional structure mainly comprise alumina Al 2 O 3 , zirconia ZrO 2 or alumina-zirconia, the composition range of which can vary from 5 to 95% by weight of alumina and 95 to 5% zirconia, preferably 10 to 90% and 90 to 10%, and particularly preferably 20 to 80% and 80 to 20%.
  • the grains may include stabilizers such as rare earth oxides, in particular yttrium oxide or cerium oxide as a stabilizer for the zirconia.
  • the millimeter grains used to manufacture the three-dimensional reinforcing structure may also comprise, in a proportion of less than 50%, preferably less than 40% and particularly preferably less than 30% by volume, titanium carbides, titanium nitrides. or some titanium carbonitrides in a third metal matrix also independent of the first two (not shown in the figures).
  • the third metal matrix serving as a binder for these millimeter grains is preferably based on an iron alloy, a nickel alloy or a molybdenum alloy.
  • the volumetric proportion of the metal binder (third metal matrix) is generally between 5 and 60%, preferably between 7 and 45% and particularly preferably between 10 and 35%.
  • the size of the titanium carbides, nitrides or carbonitrides are from 0.05 to 75 ⁇ m, preferably from 0.2 to 40 ⁇ m, more preferably from 0.5 to 15 ⁇ m.
  • the infiltrable structure therefore consists of a three-dimensional structure of an aggregate of millimeter grains of average size between 0.5 and 10 mm, preferably 0.7 to 6 mm and particularly preferably between 1 and 4 mm.
  • the interstices between the grains depend on the level of compaction and the size of the grains but are of the order of a millimeter or a fraction of a millimeter. There is thus a “periodic” alternation of grains and interstices and not a “random” alternation.
  • the millimeter grains comprise a homogeneous mixture based on alumina, zirconia or alumina-zirconia and can be agglomerated / compacted between them by the use of a binder (glue) or else kept in a metal container in order to define geometrically the reinforced area of the wearing part.
  • binder with setting via the addition of a catalyst makes it possible to produce the infiltrable structure without cooking, which may be preferred in certain cases where adequate cooking means are not available.
  • the nature of the binder is then either of organic type or of mineral type, preferably organic, more preferably of phenolic type.
  • binder with a setting by cooking allows the use of binder more resistant to high temperature.
  • the nature of the binder is then of mineral type, preferably of silicate type, more preferably of sodium silicate type.
  • the amount of binder (glue) used for producing the infiltrable structure is between 0.5% and 10% by weight, preferably between 1% and 8%, more preferably between 1.5% and 7%.
  • the amount of binder is adapted so as to ensure sufficient cohesion of the grains and to limit the production of gas during infiltration by the liquid casting metal and to limit the residual thickness of binder around each grain constituting the three-dimensional structure porous.
  • Ceramic inserts intended to be held by the three-dimensional structure of agglomerated grains, for their part, have any shape, cylindrical, polygonal or conical shapes however being preferred.
  • the diameter of these ceramic inserts, in the case of a cylindrical shape is of the order of 3 to 50 mm, preferably 6 to 30 mm, more particularly 8 to 20 mm and the length of 5 to 300 mm, preferably 10 to 200 mm, in particular 10 to 150 mm.
  • the present invention therefore describes a wear part reinforced on its most stressed side (s) obtained by the infiltration of a three-dimensional ceramic structure of agglomerated millimeter grains periodically alternating with millimeter interstices which already incorporates geometric inserts in prefabricated ceramics of ceramic-metal composite type generally obtained by powder metallurgy, where the ceramic particles are embedded in a first metal matrix completely independent of the second metal casting matrix, mainly made of steel or liquid iron.
  • This technique allows the convenient and robust positioning of inserts of defined geometry and concentrated in carbides, nitrides, metal borides or intermetallic alloys comprising a metal matrix independent of that generated by the casting.
  • This first metal matrix existing prior to the casting of said wearing part is present from the start in the ceramic-metal composite inserts.
  • the pre-existing inserts are integrated into an infiltrable structure comprising agglomerated millimeter grains (padding) of alumina, zirconia, alumina-zirconia or ceramic-metallic composite and which will be infiltrated during the casting of the wearing part.
  • the infiltrable three-dimensional structure can also include a certain proportion of millimeter grains of titanium carbides, titanium nitrides or titanium carbonitrides in a third metal matrix independent of the first two.
  • Ceramic-metal composite inserts such as a cylindrical or frustoconical insert.
  • This insert can be composed for example of titanium carbides, titanium nitrides or chromium carbides with a minimum concentration of 40% by volume in a first metal matrix based on iron, manganese, nickel or cobalt, for example, that l 'we “pack” in an infiltrable structure composed for example of an agglomerate of millimeter grains based on alumina, zirconia or alumina-zirconia.
  • this infiltrable structure can also include millimeter grains of carbides, nitrides, borides of metals or of intermetallic elements, preferably titanium carbide, titanium nitride or titanium carbonitride.
  • Alumina is known for its low load abrasion resistance properties due to its high hardness compared to the hardness of major natural minerals. Alumina also takes advantage of its low density and its low cost of implementation, whether by melting or by powder sintering.
  • Zirconia in its tetragonal crystallographic form exhibits advantageous mechanical properties for the reinforcement of parts subjected to wear.
  • Zirconia has greater flexural strength and toughness than alumina.
  • the wear resistance of zirconia is particularly good in the case where the surface stresses induced by the abrasive particles are high.
  • its lower hardness compared to certain natural minerals, including quartz or free silica limits its use when it is called upon by ores which contain it.
  • alumina-zirconia composites makes it possible to improve the properties of the two compounds taken separately, in particular the mechanical strength and the toughness.
  • the evolution of these properties is illustrated in the following figures.
  • the choice of the proportion of zirconia in the alumina makes it possible to optimize the hardness / mechanical properties-toughness pair as a function of the wear stresses to which the material is subjected in order to obtain the best performance from the part thus reinforced.
  • the present invention therefore makes it possible to achieve not only very high ceramic concentrations, generally greater than 40% by volume but up to 95% by volume in prefabricated geometric inserts or millimetric grains of pre-existing ceramic-metal composite, but also to choose the specific metal matrix (first and third metal matrix) to these elements and therefore to be independent of the casting metal (second metal matrix) of the wearing part which is generally cast iron or steel chrome.
  • the present invention allows better performance of wear parts produced in reinforced foundry compared to those of the prior art thanks to the localized increase in the wear resistance of the reinforced zone by the presence of more wear-resistant particles and / or particles of a different nature by a more suitable metal matrix. It also allows better performance of wear parts produced by adding areas of defined geometry concentrated in carbides, nitrides, metal borides or intermetallic alloys and a metal matrix existing prior to the casting of said wear part.
  • WO9815373A1 Magneticotteaux, 1997 . It is a vertical axis impactor part reinforced by a three-dimensional structure of porous and infiltrable agglomerated millimeter grains.
  • the volume of the wearing part is 10.27 dm 3 . Its mass is 74.16 kg.
  • the weight loss of the entire vertical axis impactor part is measured. This is the only way to determine the wear in practice, which depends on a series of factors and in particular on the positioning geometry in the impactor. Although being predominantly worn on the side of the reinforcement, the impactor is also partially worn outside this reinforcement depending on this positioning.
  • these grains consist of electrofused alumina-zirconia agglomerated with 3.5% by weight of inorganic binder of sodium silicate type.
  • the composition of these electrofused alumina-zirconia grains is described below.
  • This infiltrable structure comprises an aggregate of millimeter grains of average size of about 2.5 mm. These grains are agglomerated in a three-dimensional structure using sodium silicate with a predefined shape in a resin mold. In this three-dimensional structure, there is an alternation between grains and millimeter interstices.
  • This comparative example therefore presents reinforced parts based on alumina-zirconia, on the most stressed side of the wear part without initially containing centimetric ceramic-metal composite inserts, of cylinder type for example, previously positioned in a die. metal different from the ferrous alloy used for casting. At the end of these steps, a form with a total reinforced volume of 0.857 dm 3 is produced.
  • the weight loss observed during a wear test is 6.795 kg per 100 hours of operation (kg / 100h) on the wear part of the vertical axis impactor.
  • the reinforced part according to the invention comprises a reinforced zone of predefined geometry with cylindrical ceramic inserts previously manufactured at the scale of a few centimeters and previously inserted into an infiltrable structure comprising grains based on alumina-zirconia electrofused with the composition. described below. It should be noted that these grains have the same characteristics as those of the comparative example.
  • This infiltrable structure comprises an aggregate of millimeter grains of average size of about 2.5 mm. These grains are agglomerated in a three-dimensional structure using a sodium silicate-based glue with a predefined shape in a resin mold. In this three-dimensional structure, there is a periodic alternation between grains and millimeter interstices.
  • the ceramic inserts manufactured beforehand have a cylindrical geometric shape and consist on average of 70 to 80% of micrometric particles of titanium carbides bound by a first metal matrix of the austenitic steel type.
  • the diameter of these previously manufactured ceramic inserts is 20 mm.
  • the height is 30 mm.
  • the 25 ceramic inserts previously manufactured are positioned vertically with respect to the filling face in a predefined manner in the resin mold which defines the reinforcement zone thanks to notches made in the resin mold and prior to the addition of the millimeter grains of alumina-zirconia.
  • a three-dimensional structure with a total volume of 0.857 dm 3 is manufactured by casting an AFNOR Z 270 C 27 - M type cast iron.
  • This type of cast iron, which constitutes the second metal matrix, is used for all the examples.
  • Ex 1 (25 preformed inserts) 25 ceramic-metal composite inserts preformed with titanium carbide particles (70-80% vol) bound in a first metallic matrix of austenitic steel surrounded by millimeter grains of electrofused zirconia alumina (Al 2 O 3 -ZrO 2 ) Weight loss (kg / 100h) 5.022 kg
  • Example 1 is repeated but this time, 25 ceramic inserts previously manufactured are positioned identically to Example 1, but consist on average of 70 to 80% of micrometric particles of titanium carbides and of a first metal matrix. made of nickel alloy.
  • 25 ceramic-metal composite inserts preformed with titanium carbide particles (70-80% vol) bound in a first metal matrix of nickel alloy surrounded by millimeter grains of electrofused alumina-zirconia (Al 2 O 3 -ZrO 2 ) Weight loss per 100 hours (kg / 100h) 5.125kg
  • Example 1 is repeated with 25 inserts, but this time, the ceramic-metal composite inserts produced beforehand comprise on average from 75 to 85% of micrometric particles of titanium carbonitrides and a first metal matrix based on a molybdenum alloy.
  • the ceramic-metal composite inserts produced beforehand comprise on average from 75 to 85% of micrometric particles of titanium carbonitrides and a first metal matrix based on a molybdenum alloy.
  • Example 1 is repeated with again 25 inserts of the same size, but the ceramic inserts previously manufactured comprise on average from 80 to 90% of micrometric particles of chromium carbides bound in a first metal matrix based on nickel.
  • Ex. 4 25 preformed inserts
  • 25 centimetric inserts preformed with particles of chromium carbides (80-90% vol) bound with a nickel-based binder surrounded by millimeter grains of electrofused alumina-zirconia (Al 2 O 3 -ZrO 2 ) Weight loss per 100 hours (kg / 100h) 6.123kg
  • Example 4 is repeated with again 25 inserts of the same size, where the ceramic inserts previously manufactured comprise on average from 80 to 90% of micrometric particles of chromium carbides bound in a first metal matrix based on nickel.
  • the three-dimensional structure which surrounds the centimetric inserts comprises 25% by volume of millimeter grains comprising in average 80 to 85% of micrometric particles of titanium carbonitrides in a third metal matrix based on molybdenum alloy.
  • 25 centimetric inserts preformed in particles of chromium carbides (80-90% vol) bound with a nickel-based binder surrounded by millimeter grains of electrofused alumina-zirconia (Al 2 O 3 -ZrO 2 ) comprising a proportion of 25% by volume of millimeter grains of titanium carbonitrides Weight loss per 100 hours (kg / 100h) 6, 13 kg
  • the table below shows the weight losses of a wearing part of a 74.16 kg vertical axis impactor in new condition, the reinforced volume of which represents approximately 0.857 dm 3 .
  • the weight loss is measured after 438 hours of operation and is reduced over 100 hours of operation.
  • the wear mechanisms of the wear parts of vertical axis impactors are a complex mixture of material removal by abrasion, micro-chipping by microcrack propagation and impact erosion of the treated particles.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Food Science & Technology (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Crushing And Grinding (AREA)
  • Powder Metallurgy (AREA)
EP20177458.5A 2020-05-29 2020-05-29 Pièce d'usure composite Withdrawn EP3915684A1 (fr)

Priority Applications (11)

Application Number Priority Date Filing Date Title
EP20177458.5A EP3915684A1 (fr) 2020-05-29 2020-05-29 Pièce d'usure composite
BR112022023593A BR112022023593A2 (pt) 2020-05-29 2021-03-25 Peça de desgaste hierárquica e método para fabricar uma peça de desgaste
CA3185012A CA3185012A1 (en) 2020-05-29 2021-03-25 Composite wear part
EP21713434.5A EP4157538A1 (fr) 2020-05-29 2021-03-25 Piece d'usure composite
AU2021278584A AU2021278584A1 (en) 2020-05-29 2021-03-25 Composite wear part
US18/000,245 US20230201920A1 (en) 2020-05-29 2021-03-25 Composite wear part
PE2022002695A PE20231236A1 (es) 2020-05-29 2021-03-25 Pieza de desgaste compuesta
CN202180038714.XA CN115867390A (zh) 2020-05-29 2021-03-25 复合磨损部件
PCT/EP2021/057816 WO2021239295A1 (fr) 2020-05-29 2021-03-25 Piece d'usure composite
ZA2022/12082A ZA202212082B (en) 2020-05-29 2022-11-04 Composite wear part
CL2022003167A CL2022003167A1 (es) 2020-05-29 2022-11-14 Pieza de desgaste compuesta

Applications Claiming Priority (1)

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EP20177458.5A EP3915684A1 (fr) 2020-05-29 2020-05-29 Pièce d'usure composite

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EP (2) EP3915684A1 (es)
CN (1) CN115867390A (es)
AU (1) AU2021278584A1 (es)
BR (1) BR112022023593A2 (es)
CA (1) CA3185012A1 (es)
CL (1) CL2022003167A1 (es)
PE (1) PE20231236A1 (es)
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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0575685A1 (de) 1992-06-23 1993-12-29 Sulzer Innotec Ag Feinguss mit Verschleissflächen
WO1998015373A1 (fr) 1996-10-01 1998-04-16 Hubert Francois Piece d'usure composite
US20030213861A1 (en) * 2002-05-15 2003-11-20 Condon Gary J. Crusher wear components
WO2011008439A2 (en) * 2009-07-14 2011-01-20 Tdy Industries, Inc. Reinforced roll and method of making same
US20110287238A1 (en) * 2010-05-20 2011-11-24 Baker Hughes Incorporated Methods of forming at least a portion of earth-boring tools, and articles formed by such methods
WO2014125034A1 (en) * 2013-02-18 2014-08-21 Amincem S.A. Metal matrix composite useful as wear parts for cement and mining industries
WO2016008967A1 (en) 2014-07-16 2016-01-21 Magotteaux International S.A. Ceramic grains and method for their production
CN108348995A (zh) * 2015-11-12 2018-07-31 伊诺科有限责任公司 用于制造铸造嵌件的粉末组合物、铸造嵌件以及在铸件中获得局部复合区的方法

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0575685A1 (de) 1992-06-23 1993-12-29 Sulzer Innotec Ag Feinguss mit Verschleissflächen
WO1998015373A1 (fr) 1996-10-01 1998-04-16 Hubert Francois Piece d'usure composite
US20030213861A1 (en) * 2002-05-15 2003-11-20 Condon Gary J. Crusher wear components
WO2011008439A2 (en) * 2009-07-14 2011-01-20 Tdy Industries, Inc. Reinforced roll and method of making same
US20110287238A1 (en) * 2010-05-20 2011-11-24 Baker Hughes Incorporated Methods of forming at least a portion of earth-boring tools, and articles formed by such methods
WO2014125034A1 (en) * 2013-02-18 2014-08-21 Amincem S.A. Metal matrix composite useful as wear parts for cement and mining industries
WO2016008967A1 (en) 2014-07-16 2016-01-21 Magotteaux International S.A. Ceramic grains and method for their production
CN108348995A (zh) * 2015-11-12 2018-07-31 伊诺科有限责任公司 用于制造铸造嵌件的粉末组合物、铸造嵌件以及在铸件中获得局部复合区的方法

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BR112022023593A2 (pt) 2022-12-20
US20230201920A1 (en) 2023-06-29
CA3185012A1 (en) 2021-12-02
PE20231236A1 (es) 2023-08-21
WO2021239295A1 (fr) 2021-12-02
AU2021278584A1 (en) 2022-12-08
CL2022003167A1 (es) 2023-01-13
CN115867390A (zh) 2023-03-28
EP4157538A1 (fr) 2023-04-05
ZA202212082B (en) 2024-04-24

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