WO2007059568A1 - Procede de production de composites metalliques dans une atmosphere inerte et composites ainsi produits - Google Patents

Procede de production de composites metalliques dans une atmosphere inerte et composites ainsi produits Download PDF

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Publication number
WO2007059568A1
WO2007059568A1 PCT/AU2006/001762 AU2006001762W WO2007059568A1 WO 2007059568 A1 WO2007059568 A1 WO 2007059568A1 AU 2006001762 W AU2006001762 W AU 2006001762W WO 2007059568 A1 WO2007059568 A1 WO 2007059568A1
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WO
WIPO (PCT)
Prior art keywords
matrix material
substrate
temperature
matrix
liquidus temperature
Prior art date
Application number
PCT/AU2006/001762
Other languages
English (en)
Inventor
Paul Huggett
Original Assignee
Composite Alloy Products Pty Ltd
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
Priority claimed from AU2005906500A external-priority patent/AU2005906500A0/en
Application filed by Composite Alloy Products Pty Ltd filed Critical Composite Alloy Products Pty Ltd
Priority to AU2006317507A priority Critical patent/AU2006317507A1/en
Publication of WO2007059568A1 publication Critical patent/WO2007059568A1/fr

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Classifications

    • 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
    • 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

Definitions

  • the present invention relates to a method of manufacturing a wear resistant metallic composite material and to products produced by the method.
  • a range of materials are known to be available and suitable for use in various applications in wear environments. Some of the materials available for use in severe wear environments can be grouped in the following categories:
  • Each of these materials are characterised by hard carbides in a metallic matrix.
  • these materials although possessing good to excellent abrasion resistance, are not particularly easy to work with. They typically tend to be difficult, if not practically impossible, to weld. As these materials are brittle, they tend to fracture when attached to an application with mechanical fasteners, and typically fail catastrophically when subjected to high impact loads.
  • One of the ways to obtain a compromise in the material properties is to form a composite product.
  • the composite products often have an extremely wear resistant product coupled to a weldable or machineable substrate.
  • the process or the manner in which the abrasion resistant product is coupled to the tough substrate can range from mechanically interlocking to full metallurgical bonding.
  • An example of these composite products includes tungsten carbide tiles, silver soldered to carbon steel.
  • the main problem associated with this product is the bond strength.
  • the bond strength is limited because the resulting joint is predominantly mechanical and there is a need for close tolerances between the mating faces.
  • Hardfacing processes range from oxyfuel gas welding, to the various types of arc welding and also include the more advanced techniques of plasma transferred arc and laser welding. These hardfacing processes have some similarity in that a surface is coated using consumables. The consumables are selected so that the resulting coating has the desired chemical and microstructural properties.
  • All of the hardfacing techniques suffer similar problems to varying degrees.
  • the thickness of the coating is often limited and cracking of the coating is common, due to the significant thermal and shrinkage stresses placed on the applied surface and the substrate.
  • Vacuum brazing has been used successfully to join white irons to mild steel through the use of a copper-brazing alloy.
  • the parts are heated to a temperature above the melting point of the copper to allow the copper to wet both surfaces.
  • the molten copper then combines with the ferrous alloys to produce a columnar growth of copper/iron grains across the interface.
  • Carbon steel is often the substrate of choice for these composite materials because it is easy to work with basic tooling and is relatively cheap. Carbon steel also has the user-friendly properties of being easily weldable in the field using commonly and readily available techniques. This allows the wear product to be held in place by directly welding the substrate to the application, or by welding studs to the substrate and then bolting the wear product to the application.
  • a method of producing a wear resistant composite product including the steps of: contacting a first material with a second material, the first material having a liquidus temperature that is lower than a solidus temperature of the second material; heating the first and second materials in an inert gas atmosphere at a pressure greater than atmospheric pressure to a temperature above the liquidus temperature of the first material; maintaining the temperature of the first and second materials above the liquidus temperature of the first material for a predetermined period of time to at least partially fuse the first material to the second material.
  • the first material is a matrix material and the second material is a substrate material.
  • the products may be subjected to a post production heat treatment to optimize the properties of the final product for the anticipated service or for the particular requirements.
  • a post production heat treatment to optimize the properties of the final product for the anticipated service or for the particular requirements.
  • suitable control of the post production cooling cycle it may also be possible to eliminate the need for this post production heat treatment.
  • the matrix material can be chosen from a range of materials that exhibit at least partial solid solubility with the substrate material. These materials include iron, aluminium, nickel and titanium alloys, when used in conjunction with a ferrous substrate. The selection of an appropriate matrix material is largely dependent on the material characteristics and properties required of the final composite.
  • the matrix material has a composition within the following ranges in weight percent.
  • a further embodiment of the present invention includes a matrix material having a liquidus temperature of between 65O 0 C and 135O 0 C, the liquidus temperature of the matrix material being at least 100 0 C less than the solidus point of the substrate.
  • the matrix material can be manufactured in a separate process prior to the composite product manufacturing process.
  • conventional foundry techniques can be employed although advanced techniques such as atomization, forging and diecasting are also suitable.
  • the substrate material is selected from a range of materials that exhibit at least partial solid solubility with the matrix material. Predominantly, this would be a ferrous alloy,, but could include nickel or titanium base alloys. The actual analysis of this material can vary and is selectable so as to balance the solidus of the alloy with the high temperature strength and solid solubility with the matrix material.
  • the substrate material can be selected from a range of materials, in particular from those materials that are able to be welded with common welding apparatus such as mig, tig and stick welding.
  • the substrate can be in the form of a shell.
  • the furnace temperature can operate in the range of between 5O 0 C and 25O 0 C above the liquidus temperature of the matrix material.
  • the furnace is held at a temperature above the liquidus temperature of the matrix material for a predetermined period of time.
  • the furnace is typically held above the liquidus temperature of the matrix material for a minimum of 10 minutes for every 50mm of cross section of the product.
  • the inert gas atmosphere of the furnace is at a pressure greater than atmospheric pressure.
  • the inert gas atmosphere is preferably nitrogen, although argon, argon/helium, inert gas, reducing atmosphere or any other gas suitable for welding may be employed.
  • composite products manufactured according to the above described method.
  • hard carbide or ceramic material is substituted for a proportion of the matrix material, which results in products having properties of wear resistance and durability.
  • Such products are useful in applications involving extreme abrasion, where the component is subject to impact loading, or where a complex shape is required.
  • This process is also suitable for the repair of large wear components suffering extreme localised wear, such as slurry pump components and ground engaging tools.
  • the hard carbide or ceramic material includes carbides, nitrides and borides of Ti, W, Cr, Mo, Ta, V, Nb, and B.
  • the ceramic material may include oxides, nitrides and titanates of Si, Al, Mg, Ti, V, B, and Nb either individually, or in combination with any other carbide, oxide, nitride or boride wear resistant material.
  • a shell or mould used to form the shape of the component manufactured according to the inert gas casting method of the present invention.
  • the shell is a non-consumable item and is preferably coated with a refractory compound, applied to the shell.
  • the substrate may be placed on top of the matrix material and weighted thereupon, so as to keep the substrate in positive contact with the matrix material. This assembly is then heated in an electric furnace. It will be understood that various arrangements are possible using this technique and the geometry of the arrangements whereby the substrate is placed on the matrix material may vary significantly.
  • the substrate may be arranged to engage the matrix material during the heat treatment process such that when the matrix material has solidified after processing, a composite product is achieved.
  • a composite product is achieved.
  • Such embodiments could include the non-consumable mould being of a desired geometric configuration, such that the matrix material is melted and contained therein to form a composite product. In such an instance, the substrate is able to act as an insert or partial mould for the matrix material.
  • the resulting final product may consist of a number of zones, as listed below: a) the prefabricated component, forming the bulk of the substrate; b) a transition between the prefabricated component and the matrix material, where the transition is fused to the substrate c) the matrix material, which may be formed in a non-consumable mould in such a manner so as to engage the substrate or transition material.
  • Figure 1 is a flow chart showing the practical sequence of events of the method of the present invention.
  • Figure 2 is a schematic diagram illustrating production of a composite material in accordance with a method of the invention
  • Figure 3 is a phase diagram of matrix material showing liquidus range of 1175-1275 0 C;
  • Figure 4 is a typical temperature and pressure profile for a product produced in accordance with the invention, using a consumable steel shell;
  • Figure 5 is an optical micrograph of a composite product produced in accordance with the thermal and pressure profile of Figure 4, showing the interface produced between the substrate and matrix material;
  • Figure 6 is a schematic diagram illustrating production of a composite in accordance with a method of the invention, including use of a non-consumable mould;
  • Figure 7 is a typical temperature and pressure profile for a product produced with a ceramic-coated mould.
  • a trial matrix material was cast using conventional open air casting methods, the material having an approximate composition of carbon 4%, chromium 9%, manganese 1.6%, nickel 1 % and silicon 1 %.
  • This trial matrix material was cast into sand moulds to produce a base matrix material 12 for further experiments.
  • the liquidus temperature 11 for the matrix material 12 was determined by thermal analysis and cross checked with the phase diagram for the alloy system, such as that of Figure 3.
  • the liquidus line 11e is that line where the matrix material 12 changes from ausenite or M 7 C 3 carbide and liquid to liquid.
  • the substrate 14 in this example was manufactured using a conventional open-air casting process, substantially the same as for the matrix material 12.
  • the substrate 14 was in the form of a shell, nominally comprised of 0.2% carbon steel or 1% carbon tool steel. After manufacture of the matrix material 12 and the substrate 14, both are prepared for further processing by the application of high- pressure water and subsequently dried, or with mild grit blasting so as to remove any oxidation and surface scale. In other experiments the substrate 14 was fabricated using standard steel sections. To ensure the correct quantity of matrix material 12 is used, a calculation is performed on the volume of the substrate 14. Using the known density of the matrix material 12, the weight of matrix material 12 required to fill the substrate when the matrix material 12 is molten is determined, referred to as step 4 of Figure 1.
  • the prepared substrate 14 containing the required amount of matrix material 12 is placed in a furnace having the capacity for modification of atmospheric composition and pressure conditions.
  • the furnace used was an electric furnace fitted with Kanthal elements capable of reaching a maximum temperature of 1300 0 C.
  • the electric furnace sits within a mild steel casing which is capable of being pressurized during the heating cycle of the process.
  • any suitable furnace may be employed, without departing from the scope of the invention.
  • the heat treatment furnace is then purged with an inert gas to remove oxygen from the chamber.
  • the inert gas is nitrogen.
  • the heat treatment furnace is then filled with a positive pressure of the inert gas to achieve a pressure above atmospheric pressure. In this case, the furnace was filled with a positive pressure of nitrogen to 4OkPa.
  • the furnace is then set to run through a predetermined heat treatment program based on the liquidus temperature 11 of the matrix material 12 and the predetermined hold time required to obtain a product having the requisite properties for the particular application at hand.
  • the heat treatment program typically includes the steps of: a) heat-up to 1250°C to 1400 0 C; b) hold for 60 minutes ; and c) cooling to 700 0 C , it being noted that nucleation and crystal growth can be manipulated by control of the heating and cooling rates.
  • the heat treatment process is represented graphically in Figure 4.
  • the furnace is opened.
  • the substrate 14 and now remelted matrix material 12 composite products 10 are removed from the furnace and allowed to air cool to room temperature prior to final finishing processes.
  • the final product was then sectioned and examined to assess a bond interface 13 between the substrate 14 and matrix 12.
  • FIG 5 there is shown an optical micrograph of the resulting microstructure from which it was determined that the bond was fully fused and metallurgical in nature.
  • the composite product 10 consisted of a matrix material 12, in this case a wear resistant, low melting point white iron, an interface/bond 13 and a substrate 14 in the form of a consumable shell of approximately 0.2% to 1 % carbon steel.
  • the metallurgical bond 13 had an interface size of approximately 10 microns. Adjacent to the interface 13, there is a carbide depleted zone 15 within the zone that was molten during processing. This carbide depleted zone 15 can be manipulated, based on cooling rate and material composition.
  • the substrate 14 microstructure consisted of pearlite 16 with the formation of intergranular carbides 17. These may be observed as light areas adjacent the grain boundaries on the micrograph.
  • the matrix material 12 consists of austenite 18 with eutectic chromium carbides 19.
  • a bond layer 20, consisting of the bond interface 13 and the carbide depleted zone 15 has altered morphology showing a depletion of chromium. This is identified by the lack of carbides in these zones 13, 15. It can be seen that the bond layer 13 between the matrix material 12 and the substrate 14 is relatively free of porosity, with some migration of the matrix material 12 into the substrate 14.
  • the finished product was measured for dimensional accuracy and it was found that the composite product 10 had not undergone significant dimensional change.
  • the temperature profile is shown in Figure 4. This cycle is based on the liquidus temperature of the matrix material and time.
  • Figure 6 illustrates another aspect of the invention, utilising a shell or mould 26.
  • the shell or mould 26 is preferably reusable and non-consumable.
  • the mould 26 is preferably prepared and coated with a suitable refractory substance.
  • the matrix material 12 is charged into the mould 26 and a substrate 30, is arranged therein so that when the matrix material 12 melts, it fills the mould 26 and comes into intimate contact with the substrate 30 so as to fuse or partially fuse with the substrate 30.
  • the substrate can advantageously comprise an original worn part 30. In this manner, the worn part is essentially recycled, thereby assisting in cost recovery and minimisation.
  • a coating system for the mould 26 be used.
  • the mould or shell comprises a steel shell 26. This provides a non-consumable mould 26, providing that a suitable barrier coating 27 is applied to the mould 26 prior to use.
  • This barrier coating was prepared by a method including the following steps:
  • the steel shell mould is first cleaned using high-pressure water and dried, or with mild grit blasting, so as to remove any residual ceramic coatings or scale from previous use.
  • a base coat of Kaolin type refractory coating suspended in water is applied, using either a spray, flow coat or dipping method.
  • At least two thin coats of the Kaolin based refractory are applied, to obtain optimal effect. It is preferred that the coating is allowed to completely dry between application of subsequent coats.
  • topcoat of magnesite based refractory is then applied, using a suitable method of application, such as spray, flow coat or dipping. Preferably, only a single coat of the magnesite based refractory is applied.
  • the standard coating is then suspended in alcohol.
  • the final coat is then allowed to dry thoroughly prior to the mould being used.
  • the liquidus temperature of the matrix material 12 was determined either by thermal analysis during manufacture, or by using the phase diagram ( Figure 3) for the particular matrix material 12.
  • the matrix material 12 used in this example had a liquidus temperature 11 , of approximately 1190-1200 0 C.
  • the temperature above the liquidus temperature 11 to be reached and time required at this temperature during the heat treatment can be established.
  • the temperature above the liquidus temperature 11 that is required is inversely proportional with time of soak. That is, the higher the temperature of the heat treatment above the liquidus temperature 11 , the shorter the soak time required. However, the temperature above the liquidus temperature 11 that the process can be run at is limited by the solidus temperature of the substrate 14. If the operating temperature is too high, the substrate 14 or mould 26 will not have sufficient strength to hold the molten matrix material 12

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

La présente invention concerne un procédé de production d'un produit composite résistant à l'usure qui comprend les étapes suivantes: on met en contact un premier matériau avec un deuxième matériau, le premier matériau ayant une température de liquidus qui est inférieure à la température de solidus du deuxième matériau; on chauffe les premier et deuxième matériaux dans une atmosphère de gaz inerte à une pression supérieure à la pression atmosphérique classique jusqu'à une température supérieure à la température de liquidus dudit premier matériau, on maintient la température des premier et deuxième matériaux à une température supérieure à la température de liquidus du premier matériau pendant un temps prédéterminé de sorte que le premier matériau fonde au moins partiellement sur le deuxième matériau.
PCT/AU2006/001762 2005-11-22 2006-11-21 Procede de production de composites metalliques dans une atmosphere inerte et composites ainsi produits WO2007059568A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2006317507A AU2006317507A1 (en) 2005-11-22 2006-11-21 A method of manufacturing metallic composites in an inert atmosphere and composites produced thereby

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2005906500 2005-11-22
AU2005906500A AU2005906500A0 (en) 2005-11-23 A method of manufacturing metallic composites in an inert atmosphere and composites products thereby

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WO2007059568A1 true WO2007059568A1 (fr) 2007-05-31

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009155655A1 (fr) * 2008-06-27 2009-12-30 Excalibur Steel Company Pty Ltd Fabrication de composants composites résistants à l'usure
US9561562B2 (en) 2011-04-06 2017-02-07 Esco Corporation Hardfaced wearpart using brazing and associated method and assembly for manufacturing
US10543528B2 (en) 2012-01-31 2020-01-28 Esco Group Llc Wear resistant material and system and method of creating a wear resistant material

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1990001472A1 (fr) * 1988-08-05 1990-02-22 Nils Claussen Materiau ceramique composite, son procede de fabrication et son utilisation
WO1992000932A1 (fr) * 1990-07-12 1992-01-23 Lanxide Technology Company, Lp Corps en ceramique composites a teneur accrue en metal
US5511603A (en) * 1993-03-26 1996-04-30 Chesapeake Composites Corporation Machinable metal-matrix composite and liquid metal infiltration process for making same
US5702542A (en) * 1993-03-26 1997-12-30 Brown; Alexander M. Machinable metal-matrix composite
US6322608B1 (en) * 1997-11-28 2001-11-27 Daimlerchrysler Ag Method for producing a component from a composite Al2O3/titanium aluminide material

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1990001472A1 (fr) * 1988-08-05 1990-02-22 Nils Claussen Materiau ceramique composite, son procede de fabrication et son utilisation
WO1992000932A1 (fr) * 1990-07-12 1992-01-23 Lanxide Technology Company, Lp Corps en ceramique composites a teneur accrue en metal
US5511603A (en) * 1993-03-26 1996-04-30 Chesapeake Composites Corporation Machinable metal-matrix composite and liquid metal infiltration process for making same
US5702542A (en) * 1993-03-26 1997-12-30 Brown; Alexander M. Machinable metal-matrix composite
US6322608B1 (en) * 1997-11-28 2001-11-27 Daimlerchrysler Ag Method for producing a component from a composite Al2O3/titanium aluminide material

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009155655A1 (fr) * 2008-06-27 2009-12-30 Excalibur Steel Company Pty Ltd Fabrication de composants composites résistants à l'usure
AU2009262357B2 (en) * 2008-06-27 2015-10-01 Excalibur Steel Company Pty Ltd Manufacture of wear resistant composite components
US9561562B2 (en) 2011-04-06 2017-02-07 Esco Corporation Hardfaced wearpart using brazing and associated method and assembly for manufacturing
US10730104B2 (en) 2011-04-06 2020-08-04 Esco Group Llc Hardfaced wear part using brazing and associated method and assembly for manufacturing
US10543528B2 (en) 2012-01-31 2020-01-28 Esco Group Llc Wear resistant material and system and method of creating a wear resistant material

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Publication number Publication date
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