EP3915699A1 - Pièce d'usure composite céramique-métal - Google Patents

Pièce d'usure composite céramique-métal Download PDF

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Publication number
EP3915699A1
EP3915699A1 EP20177457.7A EP20177457A EP3915699A1 EP 3915699 A1 EP3915699 A1 EP 3915699A1 EP 20177457 A EP20177457 A EP 20177457A EP 3915699 A1 EP3915699 A1 EP 3915699A1
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EP
European Patent Office
Prior art keywords
carbides
metal
inserts
nitrides
casting
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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Application number
EP20177457.7A
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German (de)
English (en)
French (fr)
Inventor
Guy Berton
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.)
Magotteaux International SA
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Magotteaux International SA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Magotteaux International SA filed Critical Magotteaux International SA
Priority to EP20177457.7A priority Critical patent/EP3915699A1/fr
Priority to AU2021278197A priority patent/AU2021278197A1/en
Priority to PE2022002629A priority patent/PE20230979A1/es
Priority to PCT/EP2021/057813 priority patent/WO2021239294A1/fr
Priority to BR112022023649A priority patent/BR112022023649A2/pt
Priority to EP21713432.9A priority patent/EP4157569A1/fr
Priority to CN202180038712.0A priority patent/CN115867401A/zh
Priority to US18/000,073 priority patent/US20230211412A1/en
Priority to CA3184352A priority patent/CA3184352A1/en
Publication of EP3915699A1 publication Critical patent/EP3915699A1/fr
Priority to ZA2022/12080A priority patent/ZA202212080B/en
Priority to CL2022003198A priority patent/CL2022003198A1/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Withdrawn legal-status Critical Current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
    • B22F3/23—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces involving a self-propagating high-temperature synthesis or reaction sintering step
    • 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
    • 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
    • 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
    • B22F1/05—Metallic powder characterised by the size or surface area of the 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
    • 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
    • B22F3/004—Filling molds with powder
    • 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
    • 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
    • C22C1/047—Making non-ferrous alloys by powder metallurgy comprising intermetallic compounds
    • 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
    • C22C1/04—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
    • C22C1/053—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor with in situ formation of hard compounds
    • 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
    • C22C1/053—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor with in situ formation of hard compounds
    • C22C1/055—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor with in situ formation of hard compounds using carbon
    • 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
    • C22C1/058—Mixtures of metal powder with non-metallic powder by reaction sintering (i.e. gasless reaction starting from a mixture of solid metal compounds)
    • 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
    • C22C1/1047—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
    • C22C1/1052—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites by mixing and casting metal matrix composites with reaction
    • 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
    • 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
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1073—Infiltration or casting under mechanical pressure, e.g. squeeze casting
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/22—Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/24—Ferrous alloys, e.g. steel alloys containing chromium with vanadium
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/20—Refractory metals
    • B22F2301/205—Titanium, zirconium or hafnium
    • 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
    • B22F2302/10—Carbide
    • 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
    • B22F2302/40—Carbon, graphite

Definitions

  • the present invention relates to a wear part produced in a foundry. It relates more particularly to a wearing part comprising a reinforced part according to a predefined geometry with ceramic inserts previously manufactured inserted in an infiltrable structure comprising precursor reagents for the formation of ceramics during the casting by self-propagating exothermic reaction. .
  • 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.
  • the composite wear parts produced by casting in a foundry comprising parts reinforced by ceramics created in situ during the casting by a self-propagating exothermic reaction initiated by the heat of the casting are well known in the state of the art. .
  • the document WO03 / 047791 offers a wear part with a series of ceramics such as carbides, nitrides, borides or intermetallic alloys formed in situ during a self-propagating exothermic reaction (SHS).
  • SHS self-propagating exothermic reaction
  • the documents WO2010 / 031660 ; WO2010 / 0311661 ; WO2010 / 031663 and WO 2010/031662 offer wear parts with titanium carbide formed in situ by self-propagating exothermic reaction. It is a hierarchically reinforced structure where the reactants are agglomerated with an inorganic glue in the form of millimeter grains assembled in a "cake" (padding) to form an infiltrable geometric structure during the exothermic reaction self-propagated and initiated by casting.
  • This technology creates a structure with an alternation of areas with a low and high concentration of titanium carbide globules, the areas with high concentration being located at the location of the grains of reactants (here, carbon and titanium) precursors of the reaction of formation of titanium carbide.
  • 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 ceramics (> 50% by volume for example). It also aims to integrate areas with a high concentration of ceramics in the form of inserts of predefined geometry within an infiltrable structure of ceramic precursor reagents making it possible at the same time to ensure the adequate maintenance of the reinforced parts in the mold during casting of the wearing part.
  • the present invention discloses a wear part comprising a reinforced part comprising a ferrous alloy reinforced with carbides, nitrides, metal borides or with intermetallic alloys where said reinforced part comprises inserts of predefined geometry, said inserts comprising micrometric particles of carbides , metal nitrides, borides or intermetallic compounds prefabricated and coated in a first metal matrix (10), said inserts being inserted in a infiltrated reinforcement structure comprising a periodic alternation of areas with a high and low concentration of micrometric particles of carbides, nitrides, metal borides or intermetallic alloys obtained from agglomerated grains comprising the reagents necessary for an exothermic synthesis self-propagated in situ triggered during the casting of the ferrous alloy, said ferrous alloy forming the second metal matrix, the latter being different from said first metal matrix.
  • the present invention also discloses main applications 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 wearing part comprising a reinforced part according to a predefined geometry with ceramic inserts at the scale of a few centimeters previously manufactured inserted into an infiltrable three-dimensional structure made up of agglomerated millimeter grains and forming a periodic alternation of grains and millimeter interstices.
  • the grains contain reagents necessary for the formation of ceramics during the casting by a self-propagating exothermic reaction.
  • the infiltrable structure therefore consists 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.
  • the millimeter grains contain a homogeneous mixture of reactive powders with, if necessary, a moderating powder and can be agglomerated / compacted between them by the use of a binder or kept in a metal container in order to geometrically delimit the reinforced zone of the part. 'wear.
  • the ceramic inserts previously manufactured and intended to be held by the three-dimensional structure of agglomerated grains, for their part, have any shape, a cylindrical shape or of approximately cylindrical type being however preferred.
  • the size of these ceramic inserts previously manufactured in the case of a cylindrical shape is of a diameter of 3 to 50 mm, preferably 6 to 30 mm, more particularly 8 to 20 mm and a height 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 side or sides most stressed by, on the one hand, a preformed ceramic (ceramic-metal composite) generally obtained by powder metallurgy comprising a first metal matrix binding the micrometric particles. of ceramics, and on the other hand, of a ceramic formed in situ during the casting of steel or liquid iron (the second metal matrix), the first metal matrix being completely independent of the first metal matrix, this which makes it manageable to measure.
  • a preformed ceramic ceramic-metal composite
  • This technique allows the convenient and robust positioning of prefabricated inserts of defined geometry and concentrated in carbides, nitrides, metal borides or intermetallic alloys and comprising a metal matrix independent of that generated by the casting.
  • This metal matrix existing prior to the casting of the wear part is present from the start in the ceramic-metal composite inserts integrated in an infiltrable structure formed of agglomerated millimeter grains (padding) comprising the reagents necessary for the formation of ceramic materials necessary for a self-propagating exothermic reaction and which will be formed during the casting of the wearing part by initiation of an SHS reaction (“self-propagating high-temperature synthesis” in English: https://en.wikipedia.org/wiki/Self-propagating high-temperature synthesis ).
  • preformed ceramic-metal composite inserts are used here partially, for example 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 (compositions of type DIN 1.3401, or DIN 2.4771 for example) which is "wrapped" in an infiltrable structure composed for example of an agglomerate of millimeter grains of a mixture of carbon and titanium, optionally diluted by a moderator such as powder iron or steel (for example 45CrMoV67 steel), which will be transformed during the casting of the wearing part by self-propagating exothermic reaction in TiC formed in situ.
  • a moderator such as powder iron or steel (for example 45CrMoV67 steel), which will be transformed during the casting of the wearing part by self-propagating exothermic reaction in TiC formed in situ.
  • This TiC formed in situ and infiltrated at least partially by the casting metal will produce a “hybrid” structure with areas of high TiC concentration at the location of the geometric inserts previously fabricated with their own metal matrix (first metal matrix based on Ni, Mn, Co, steel, Ni alloy), at least partially surrounded by a structure where the ceramics will have been formed in situ and where the interstices will have been infiltrated by the casting metal of the part. wear.
  • agglomerated reactants Ti + C for example
  • TiC should not be interpreted in the strict chemical sense of the term but as titanium carbide in the crystallographic sense because titanium carbide has a wide composition range from a stoichiometric C / Ti ratio of 0.47 to 1.
  • other ceramics such as nitrides and borides for example, the stoichiometric variations of which can be relatively wide.
  • the present invention therefore makes it possible to achieve not only very high ceramic concentrations, generally greater than 40% by volume, which can range up to 90% by volume in prefabricated inserts, but also to choose the first metal matrix specific to these. prefabricated inserts and therefore to be independent of the casting metal (second metal matrix) of the wearing part, which is often cast iron or chrome steel.
  • the reagents used to produce the infiltrable structure of agglomerated millimeter grains can be chosen from the group of ferroalloys, preferably FerroTi, FerroCr, FerroNb, FerroW, FerroMo, FerroB, FerroSi, FerroZr or FerroV.
  • They can also belong to the group of oxides, preferably TiO 2 , FeO, Fe 2 O 3 , SiO 2 , ZrO 2 , CrO 3 , Cr 2 O 3 , B 2 O 3 , MoO 3 , V 2 O 5 , CuO , MgO and NiO, or from the group of metals or their alloys, preferably iron, nickel, titanium or aluminum on the one hand and on the other hand, on the other hand, carbon, boron or nitrided compounds for forming the corresponding carbides, borides or nitrides.
  • oxides preferably TiO 2 , FeO, Fe 2 O 3 , SiO 2 , ZrO 2 , CrO 3 , Cr 2 O 3 , B 2 O 3 , MoO 3 , V 2 O 5 , CuO , MgO and NiO
  • metals or their alloys preferably iron, nickel, titanium or aluminum on the one hand and on the other hand, on the other hand, carbon, boron or n
  • the geometric ceramic inserts previously manufactured can be made of titanium carbides, titanium nitrides, titanium carbonitrides, chromium carbides, chromium nitrides, chromium carbonitrides, carbides of niobium or tungsten carbides, taken singly or as a mixture with one another.
  • the present invention allows better performance of wear parts produced in reinforced foundry than those of the prior art thanks to the increase localized wear resistance of the area reinforced 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 the wearing parts produced by the addition of zones of defined geometry concentrated in carbides, nitrides, metal borides or in intermetallic alloys and of a first metal matrix existing prior to the casting of said part.
  • the resistance of a reinforced part is measured. It is manufactured in a manner analogous to the process disclosed in the prior art ( WO2010 / 031663 ).
  • This prior art presents a composite impactor for impact mills comprising a ferroalloy which is reinforced on its side most exposed to wear with a three-dimensional structure of millimetric grains precursors of titanium carbide. It is carried out by self-propagating exothermic synthesis in situ. The impactor weighs 52 kg and is reinforced in a volume of approximately 0.88 dm 3 .
  • This comparative example therefore presents reinforced parts of titanium carbides produced exclusively by self-propagating thermal synthesis of titanium and carbon in situ to form titanium carbide during casting.
  • the reaction is triggered by the casting of the ferrous alloy consisting of a martensitic stainless steel of the 12CrMoV type which will also be used for the examples according to the invention.
  • This wear part therefore only contains a three-dimensional structure of alternating areas of high and low concentration of titanium carbides produced in situ on the side most stressed of the wear part during casting without initially containing ceramic composite inserts.
  • metal of the cylinder type for example, previously formed in a metal matrix different from the ferrous alloy used for the casting.
  • a form with a total reinforced volume of 0.88 dm 3 is produced.
  • the weight loss observed during a wear test is 3.63 kg per 100 hours of operation (kg / 100h) on the composite impactor for impact crushers.
  • the same conditions of use and of material to be ground will be reproduced.
  • the reinforced part according to the invention comprises a reinforced zone of predefined geometry with ceramic inserts previously manufactured at the scale of a few centimeters and previously inserted into an infiltrable structure comprising the reagents necessary for the formation of ceramics during reaction casting. self-propagating exothermic.
  • This infiltrable structure consists of an aggregate of millimeter grains with an average size of about 2.5 mm containing the reagents necessary for the reaction. These grains are agglomerated in a three-dimensional structure using an organic binder of the phenolic resin type with a predefined shape in a resin mold. In this three-dimensional structure, there is a periodic alternation between grains and millimeter interstices. This configuration is shown in the figure 7 .
  • These grains comprise a mixture of titanium powder with an average particle size of 60 ⁇ m and a purity of 98%, graphite powder with an average particle size of 30 ⁇ m and a purity of 99% and steel powder with an average particle size of 60 ⁇ m and comprising a steel powder of 45CrMoV67 type as reaction moderator. These millimeter grains are compacted with a porosity of less than 20%.
  • the chemical composition of these grains is given in the following table for 100 kg of grains. Titanium Carbon Moderator 45 CrMoV steel 6 7 63.82 kg 14.70 kg 21.48 kg
  • the ceramic inserts previously manufactured have a cylindrical geometric shape.
  • the diameter of these previously manufactured ceramic inserts is 12mm, the height is 20mm.
  • They consist of 70-80% titanium carbides, 1-3% chromium carbides and a binder based on austenitic manganese steel type DIN 1.3401. This binder constitutes the first metal matrix.
  • a three-dimensional structure with a total volume of 0.88 dm 3 is produced by casting a 12CrMoV type alloy of composition: 0.15-0.20% C; 9.00-11.00% Cr; 0.60-1.10% Mn and 0.35-0.65% Si. This constitutes the second metal matrix.
  • Example 1 is repeated but this time, 77 ceramic inserts manufactured beforehand are positioned 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. reagents intended for the self-propagating exothermic reaction which will be agglomerated thanks to the same organic binder. At the end of these steps, a three-dimensional structure with a total volume of 0.88 dm 3 , similar to the figure 2 is manufactured.
  • the ceramic inserts previously manufactured consist of 70-80% titanium carbides, 1-3% chromium carbides and a binder as a first metal matrix based on austenitic manganese steel type DIN 1.3401.
  • Example 1 is repeated with 67 inserts but this time, the ceramic inserts previously manufactured contain 75-85% titanium carbonitrides and a binder based on a nickel and chromium alloy of the DIN 2.4771 type as the first metal matrix. .
  • Ex. 3 (67 preformed inserts) alloy of titanium carbides and nitrides (75-85%) surrounded by precursor reagents in titanium grains + carbon with steel moderator 45 CrMoV 6 7 Weight loss per 100 hours (kg / 100h) 1.95 Coefficient of superiority compared to the comparative example 1.86
  • These particles consist of a mixture of titanium powder with an average particle size of 60 ⁇ m and a purity of 98%, vanadium powder with a particle size less than 200 mesh and graphite powder with a particle size less than 30 ⁇ m and a purity of 99% . These particles are compacted with a porosity of less than 22%.
  • the chemical composition of these particles is given in the following table. Titanium Carbon Vanadium 67.01 kg 31.23 kg 71.32 kg
  • Example 1 is repeated with again 67 inserts of the same size but the ceramic inserts previously manufactured now contain 70-80% of chromium carbides and a binder based on a nickel and chromium alloy of type DIN 2.4771 as first metal matrix.
  • Ex. 4 (67 preformed inserts) Chromium carbide inserts (70-80%) surrounded by precursor reagents in titanium + carbon + vanadium grains Weight loss per 100 hours (kg / 100h) 2.23 Coefficient of superiority compared to the comparative example 1.63
  • These particles consist of a mixture of titanium powder with a particle size of approximately 60 ⁇ m and a purity of 98%, boron carbide powder with a particle size less than 150 mesh and graphite powder with an average particle size of 30 ⁇ m and purity 99%.
  • the 67 ceramic inserts previously manufactured contain 80-90% chromium carbides and a binder based on an alloy of nickel and chromium type 2.4771 as the first metal matrix.
  • Chromium carbide inserts (80-90%) surrounded by precursor reagents in titanium + carbon grains mixed with boron carbide Weight loss per 100 hours (kg / 100h) 2.72 Coefficient of superiority compared to the comparative example 1.33
  • SHS self-propagating exothermic synthesis
  • These precursor grains comprise a mixture of titanium powder with an average particle size of approximately 60 ⁇ m and a purity of 98%, of graphite powder with an average particle size of 30 ⁇ m and a purity of 99%. These millimetric precursor grains of approximately 2.5 mm are compacted with a porosity of less than 20%.
  • the chemical composition of these grains is given in the following table per 100 kg of grains. Titanium Carbon Alumina-zirconia / titanium oxide 60/39 / 0.15 and as moderator 63.95 kg 16.05 kg 20.00 kg
  • the non-reactive grains comprise alumina-zirconia with a proportion of 60% alumina and 39% zirconia and 0.15% titanium oxide.
  • the average size of these non-reactive millimeter grains is 2.1 mm.
  • Previously manufactured ceramic inserts consist on average of 70-80% titanium carbides, 1-3% chromium carbides and a binder with DIN 1.3401 type austenitic manganese steel base constituting the first metal matrix.
  • the proportion by weight of non-reactive grains relative to the precursor grains of the exothermic reaction can vary in volume between 5 and 40%, preferably between 10 and 30%, more preferably between 15 and 20%. In this specific example, it is 20% by weight.
  • the table below shows the weight losses of a 52 kg impactor in new condition, the reinforced volume of which represents approximately 0.88 dm 3 .
  • the weight loss is measured after 696 hours of operation and is reduced over 100 hours of operation.
  • Titanium + carbon + moderating steel powder 45 CrMoV 67 - - 3.63 - 1 Titanium + carbon + moderating steel powder 45 CrMoV 67 alloy of titanium and chromium carbides (70-80%) 67 2.02 80 2 Titanium + carbon + moderating steel powder 45 CrMoV 67 alloy of titanium and chromium carbides (70-80%) 77 2.06 76 3 Titanium + carbon + moderating steel powder 45 CrMoV 67 alloy of carbides and titanium nitride (75-85%) 67 1.95 86 4 Titanium + carbon + Vanadium Chromium carbides (70-80%) 67 2.23 63 5 Titanium + carbon + boron carbide Chromium carbides (80-90%) 67 2.72 33 6 Titanium + carbon + non-reactive grains containing alumina - zirconia alloy of titanium and chromium carbides (70-80%) 67 2.82 29
  • the wear performance of the various examples is a combination of the wear rate of the reinforcement surrounding the preformed insert, of the preformed insert itself as well as of the unreinforced area of the impactor. Thus, the wear rates of these different areas were evaluated in order to explain the difference in performance of the different examples.
  • the wear resistance of ceramic-metal composites depends on the properties of the ceramic particles, their proportion and their distribution as well as the nature of the binder used.
  • Example 5 It also follows that chromium carbides are more fragile than titanium-based carbides or carbonitrides. This explains why the performance of Example 5 is lower than that of Example 4 despite a higher percentage of chromium carbides in the preformed inserts.

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EP20177457.7A EP3915699A1 (fr) 2020-05-29 2020-05-29 Pièce d'usure composite céramique-métal
EP21713432.9A EP4157569A1 (fr) 2020-05-29 2021-03-25 Piece d'usure composite ceramique-metal
PE2022002629A PE20230979A1 (es) 2020-05-29 2021-03-25 Pieza de desgaste compuesta de ceramica y metal
PCT/EP2021/057813 WO2021239294A1 (fr) 2020-05-29 2021-03-25 Piece d'usure composite ceramique-metal
BR112022023649A BR112022023649A2 (pt) 2020-05-29 2021-03-25 Peça de desgaste e método para fabricar uma peça de desgaste
AU2021278197A AU2021278197A1 (en) 2020-05-29 2021-03-25 Ceramic-metal composite wear part
CN202180038712.0A CN115867401A (zh) 2020-05-29 2021-03-25 陶瓷-金属复合磨损部件
US18/000,073 US20230211412A1 (en) 2020-05-29 2021-03-25 Ceramic-metal composite wear part
CA3184352A CA3184352A1 (en) 2020-05-29 2021-03-25 Ceramic-metal composite wear part
ZA2022/12080A ZA202212080B (en) 2020-05-29 2022-11-04 Ceramic-metal composite wear part
CL2022003198A CL2022003198A1 (es) 2020-05-29 2022-11-16 Pieza de desgaste compuesta de cerámica y metal

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ZA202212080B (en) 2024-04-24
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CN115867401A (zh) 2023-03-28
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