WO2010058075A1 - Procédé de préparation d'un multimatériau résistant à l'usure et utilisation du multimatériau - Google Patents

Procédé de préparation d'un multimatériau résistant à l'usure et utilisation du multimatériau Download PDF

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Publication number
WO2010058075A1
WO2010058075A1 PCT/FI2009/050928 FI2009050928W WO2010058075A1 WO 2010058075 A1 WO2010058075 A1 WO 2010058075A1 FI 2009050928 W FI2009050928 W FI 2009050928W WO 2010058075 A1 WO2010058075 A1 WO 2010058075A1
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WO
WIPO (PCT)
Prior art keywords
wear
billet
hot
multimaterial
materials
Prior art date
Application number
PCT/FI2009/050928
Other languages
English (en)
Inventor
Jari Liimatainen
Jussi Hellman
Original Assignee
Metso Minerals, Inc.
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 Metso Minerals, Inc. filed Critical Metso Minerals, Inc.
Publication of WO2010058075A1 publication Critical patent/WO2010058075A1/fr

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Classifications

    • 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
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00—Casting ingots, e.g. from ferrous metals
    • B22D7/02—Casting compound ingots of two or more different metals in the molten state, i.e. integrally cast
    • 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

Definitions

  • the invention relates to a method for preparing a wear-resistant multimaterial, particularly for preparing a bi-metallic, cast and hot-worked wear steel.
  • the invention relates to the use of a multimaterial prepared by such a method.
  • the wear-resistance, such as the abrasion resistance, of steels and iron-based materials is mainly increased by two principal methods:
  • the latter of these methods is more effective, because the particles in the metallic matrix which are very hard and harder than the abrasive particles most efficiently prevent the penetration of abrasive particles into the metal and the wearing of the metal by a cutting wear mechanism.
  • the hardest carbides have a hardness of about 3000 HV (vanadium carbide), whereas purely by means of a heat treatment a hardness level of about 650 to 700 HV at most can be produced in the metal.
  • Increasing the wear resistance by means of carbides produced in the microstructure decreases toughness substantially, because the carbides crack through nucleation of cracks and materials loss cracks which are easily induced because of wear loads.
  • Large carbides or carbide networks producing continuous networks for example on grain boundaries are therefore particularly detrimental.
  • the embrittling effect of carbides can be reduced by preventing the formation of continuous carbide networks (typical i.a. for cast materials such as white cast iron).
  • Another way of reducing the embrittling effect of carbides is to orientate the carbides so that their longitudinal dimension is perpendicular to the wear surface.
  • the combination of toughness and wear resistance can be optimized. With respect to wear materials, it is crucial to avoid macroscopic cracking of the material.
  • Detaching of large objects from wear parts and their passing to a subsequent stage of the process may cause serious damages and an interruption of use in the whole facility.
  • One way is to prepare a component so that the whole component is not prepared from a crack-sensitive material and a breakage of a brittle wear-resistant material will only cause a limited break and the detachment of a piece.
  • powder metallurgy One way of preparing high-alloy materials containing a very large amount of small carbides is powder metallurgy.
  • powder metallurgical methods a high- alloy powder is first prepared by gas atomization, which powder is compacted to a compact material by hot isostatic pressing. When needed, the hot isostatically pressed material can be hot- worked later to a desired dimension and shape.
  • the disadvantage of the powder metallurgical manufacturing method is its high cost.
  • the carbide size obtained by the method typically an average size less than 5 ⁇ m, is not suitable for all heavy wear conditions.
  • the manufacturing method according to the present invention is able to remove or at least to essentially reduce the above presented disadvantages of the prior art.
  • the material Owing to the tough material surrounding the starting billet and to the process metallurgical method, such as for example electro slag remelting, vacuum arc remelting or spray forming, which is used for preparing the hard wear-resistant material, the material is hot-workable.
  • the machinability of the tough material surrounding the billet is clearly better than that of the wear-resistant material, which facilitates the machining of the outer surface of the billet to precise mounting and connection dimensions.
  • the orientation of the carbide network of the wear-resistant material along the longitudinal dimension of the billet during hot-working can be utilized in wear parts by using preferably the heavy-wear resistant cross-sectional surface as the wear surface.
  • ESR electro slag remelting
  • VAR vacuum arc remelting
  • spray forming for manufacturing the wear-resistant material, so that the homogeneity of the billet and the hot-working properties of the structure can be improved.
  • ESR electro slag remelting
  • VAR vacuum arc remelting
  • spray forming for manufacturing the wear-resistant material, so that the homogeneity of the billet and the hot-working properties of the structure can be improved.
  • lower-alloy materials also traditional casting methods can be used.
  • the method according to the invention is characterized by what is disclosed in the characterizing part of claim 1, and the use of the multimaterial prepared by the method according to the invention is characterized by what is disclosed in claim 10.
  • Figure Ia shows schematically a structure of a starting billet used in the method according to the invention
  • Figure Ib shows the starting billet of Figure Ia after hot- working
  • Figure 2a shows schematically, before hot-working, large carbides in a cast starting billet used in the method according to the invention
  • Figure 2b shows the carbides of Figure 2a after hot- working
  • Figure 3 a shows schematically as a side view the location of material layers in a material prepared by the method according to the invention, and Figure 3b shows from above the location of the material layers of the material of Figure 3a.
  • Figure Ia shows a starting billet 100 used in the method according to the invention, which billet comprises a tough cast material 101, a wear-resistant material 102, a mold plate 103 and a mold 104.
  • a billet consisting of two or more materials is prepared.
  • the materials are chosen so that at least one of them is a wear-resistant iron- based (Fe > 50 wt-%) material and at least one is a tough mechanically robust iron-based material (Fe > 50 wt-%).
  • After manufacturing the billet it is hot-worked by means of pressure and temperature for example by hot forging, hot rolling or hot isostatic pressing.
  • the billet 100 can be prepared in a number of ways depending on the materials to be used.
  • the materials to be used are chosen in accordance with the material constraints imposed by the object, whereby the choice is affected i.a. by the loads on the material, wear conditions etc.
  • a billet 100 is prepared by static casting in a casting-technical sense, i.e. by casting to a solid mold, whereby two different materials are cast in sections of the mold 104, which materials are cast in different sections of the mold so that they are not mixed with each other.
  • This can be carried out for example by placing a metallic divider plate 103 in the mold 104 for separating the regions formed by the two different materials 101 and 102 from each other.
  • both materials 101 and 102 melt the metallic divider plate 103 partly but not completely, however, whereby the materials 101 and 102 do not become mixed with each other.
  • a billet 100 is formed, which billet, after solidification, is ready for being hot- worked to its final shape, as shown in Figure Ib.
  • This hot-working additionally provides the compaction of the billet 100 and the desired changes in the microstructure, i.a. the desired orientation of the microstructure and its properties.
  • the wear-resistant and more brittle material is hot- workable in cast condition without being cracked and the component damaged.
  • An alternative way according to the invention for the above described method is especially to prepare billets containing particularly high-alloy materials so that the billet 100 is prepared by electro slag remelting, vacuum arc remelting or spray forming so that segregation of the high-alloy material is minimized, whereby its purity level remains as high as possible.
  • a starting billet is first prepared from desired starting materials, after which it is melted as tiny droplets through a hot slag, whereby its purity level is increased. At the same time it is possible to reduce segregation mostly owing to the longitudinal solidification of the billet, whereby the quality of all billet materials is homogeneous. Thanks to this, the material has a better hot-workability than a traditionally cast and solidified material, and its working characteristics are better.
  • vacuum arc remelting the starting billet is melted as tiny droplets without slag by means of an electric arc generated between the starting billet and the basic plate of a copper mold.
  • the molten metal In spray forming the molten metal is decomposed into small " partly molten droplets by means of the kinetic energy of a gas spray, which droplets are collected to a collector plate before they are completely solidified, on which collector plate a metallic billet is thus deposited. Because the solidification rate is fast in spray forming, the homogeneity of the structure is very good.
  • the billet 100 can be prepared in the above-described manner so that the tougher and less crack-sensitive material 201 surrounds the more brittle material 202 with an inferior hot- workability, as shown in Figures 2a and 2b. Even if cracks were formed in the more brittle material 202 which is surrounded by the tougher material 201, particularly in the initial stage of hot-working, they will not open up to the surface and become oxidized, whereby these cracks will heal up when hot-working is continued. The success of hot- working is also promoted by the fact that by preparing the billet by electro slag remelting its hot-workability will be better than that of a material prepared by static casting.
  • the tougher billet surrounding the more wear-resistant material can be prepared separately for example by bending from a plate, by machining a hole in a billet or by preparing a cast billet.
  • the surrounding material can also be sealed entirely by welding covers to both ends of the billet. In certain situations the billet can even be prepared by casting a tough material around a wear-resistant material.
  • carbides 203 When particularly high-carbon materials (C > 1 wt-%) and a sufficient amount of carbide-forming substances are used as the wear-resistant material 202, relatively large carbides 203 (with a size greater than 20 ⁇ m) are obtained in the structure.
  • the advantage of the carbides of this size is their advantageous effect on heavy-abrasion resistance.
  • these carbides 203 become further oriented so that their longitudinal axis is parallel to the longitudinal axis of the hot- worked material, as shown in Figure 2b. If the material can be used so that the surface exposed to heavy abrasion is a surface perpendicular to the longitudinal dimension of the worked material, i.e. a cross-sectional surface with respect to the longitudinal axis of the formed billet, the microstructure of the wearable material may be particularly preferred.
  • Figure 3 a shows as a cross-section and as a side view an alternative embodiment according to the invention for the billet shown in Figures 2a and 2b.
  • the wear-resistant material 202 is located as island-like regions surrounded by the tough material 201.
  • Figure 3b shows the arrangement according to Figure 3 a from above.
  • the distribution and orientation of the hard phases 203 of the wear-resistant material can be changed to more advantageous with respect to wear-resistance and often also with respect to mechanical properties in the forming stage.
  • the materials to be used shall be chosen so that they are suitable for the intended operating conditions with respect to mechanical properties and wear-resistance.
  • the tougher material which is supposed to surround the more brittle and more wear-resistant material, should have such a toughness and fatigue resistance that it will not break or fatigue in normal operating conditions.
  • the carbide concentration of the material should be limited to less than 10 vol-%, in particularly demanding objects to less than 5 vol-%.
  • a weaker toughness can be accepted with respect to mechanical properties, because the tough material surrounding it is intended for preventing any break-induced detachment of pieces from the brittle material.
  • the hot- workability of the material is sufficiently good so that the hot-working can be carried out without breakage of the material.
  • electro slag remelting particularly for high-alloy materials (C > 1.5 wt-%, Cr+Mo+V+W > 10 wt-%, preferably C > 1.5 wt-% and Cr+Mo+V+Nb+W > 12 wt-%), to ensure a sufficient hot-workability and mechanical properties. For lower-alloy materials even normal casting processes can be employed.
  • the billet can be prepared for example so that a pipe is manufactured from a thick steel plate, inside of which pipe a high-alloy wear-resistant material is cast.
  • the cast material of the starting billet can preferably be prepared for example by one of the following methods:
  • the wear-resistant material contains a sufficient amount of carbides to provide the wear-resistance required in the application, the wear-resistant material is surrounded by a tough easily formable material, and that the structure is finally hot-worked to orientate the structure, to compact the cast structure and to decompose eventual carbide networks by means of pressure and temperature for example by hot forging, hot rolling or hot isostatic pressing.
  • the manufacturing method of the wear-resistant material must be chosen so that it is hot- workable.
  • a high-alloy wear-resistant material is used at least as one of the cast materials, which high-alloy wear-resistant material contains at least 50 wt-% Fe, at least 0.8 wt-% C and additionally at least 10 wt-% of one or more of the carbide-forming substances: Cr, Mo, V, Nb and W.
  • At least one of the cast materials is a high-carbon and high-chromium material which contains over 1.5 wt-% C and over 12 wt-% Cr.
  • the microstructure of the wear-resistant material preferably, when the method according to the invention is used, becomes such that it is able to reduce wearing in view of several applications.
  • the wear-resistant cast material in the structure of the starting billet is surrounded at least partly by a tough Fe-, Ni- or Co-based material in which the amount of carbides is less than 10 vol-% so that preferably at most 40 % of the cross-sectional surface of the billet is tough material.
  • the starting billet has been hot isostatically pressed before hot-working to improve structural integrity and uniformity.
  • the embodiment according to the invention is suitable for preparing all kinds of wear surfaces.
  • the wear material prepared by the method according to the invention is preferably suitable for use in all kinds of wear materials and wear parts, such as crushing and wear parts of crushing and grinding machinery of mineral material which are used in the excavation and mining industry.
  • the invention is not intended to be limited to the embodiments described above by way of example but it can be applied widely within the scope determined by the following claims.

Abstract

L'invention porte sur un procédé de préparation d'un multimatériau résistant à l'usure et sur l'utilisation du multimatériau, lequel procédé comprend la préparation d'une billette de multimatériau de départ à l'aide de la technologie de coulage pour préparer au moins l'un des matériaux devant être utilisés dans la billette, ledit matériau préparé par la technologie de coulage étant un matériau résistant à l'usure et fortement allié, qui contient au moins 50 % en poids de Fe, au moins 0,8 % en poids de C et de plus au moins 10 % en poids au total d'une ou de plusieurs des substances formant des carbures suivantes : Cr, Mo, V, Nb, W. Dans le procédé, la billette de départ est travaillée à chaud pour obtenir une section transversale déterminée.
PCT/FI2009/050928 2008-11-18 2009-11-17 Procédé de préparation d'un multimatériau résistant à l'usure et utilisation du multimatériau WO2010058075A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20086087 2008-11-18
FI20086087A FI20086087A (fi) 2008-11-18 2008-11-18 Menetelmä kulumiskestävän monimateriaalin valmistamiseksi sekä monimateriaalin käyttö

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WO2010058075A1 true WO2010058075A1 (fr) 2010-05-27

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010119179A2 (fr) * 2009-04-17 2010-10-21 Metso Minerals, Inc. Procédé de préparation d'un élément de revêtement de broyeur et utilisation de cet élément

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH344093A (de) * 1954-08-23 1960-01-31 Hocke Ernst Dr Jur Verfahren zur Herstellung von hochverschleissfesten Stählen sowie ein nach diesem Verfahren hergestellter Stahl und dessen Verwendung
DE1212252B (de) * 1961-05-24 1966-03-10 Kloeckner Werke Ag Trennblech zum Einsetzen in Kokillen fuer die Herstellung von Verbundgussblechen aus Stahl
JPS609551A (ja) * 1983-06-29 1985-01-18 Hitachi Ltd 複合材の溶製方法
AT387187B (de) * 1984-11-12 1988-12-12 Santrade Ltd Verbundkoerper und verfahren zu seiner herstellung
DE3807347A1 (de) * 1988-03-05 1989-09-14 Werner Schatz Formkoerper aus mehreren metallschichten sowie verfahren zu ihrer herstellung
WO2004039521A1 (fr) * 2002-11-01 2004-05-13 Metso Powdermet Oy Procede de fabrication de parties en multimateriaux et partie en multimateriaux

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH344093A (de) * 1954-08-23 1960-01-31 Hocke Ernst Dr Jur Verfahren zur Herstellung von hochverschleissfesten Stählen sowie ein nach diesem Verfahren hergestellter Stahl und dessen Verwendung
DE1212252B (de) * 1961-05-24 1966-03-10 Kloeckner Werke Ag Trennblech zum Einsetzen in Kokillen fuer die Herstellung von Verbundgussblechen aus Stahl
JPS609551A (ja) * 1983-06-29 1985-01-18 Hitachi Ltd 複合材の溶製方法
AT387187B (de) * 1984-11-12 1988-12-12 Santrade Ltd Verbundkoerper und verfahren zu seiner herstellung
DE3807347A1 (de) * 1988-03-05 1989-09-14 Werner Schatz Formkoerper aus mehreren metallschichten sowie verfahren zu ihrer herstellung
WO2004039521A1 (fr) * 2002-11-01 2004-05-13 Metso Powdermet Oy Procede de fabrication de parties en multimateriaux et partie en multimateriaux

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
A. HARNISCH, A. BUCHHOLZ, F. HILLEBRAND: "Ein neu entwickelter Verbundgussstahl für auf Verschleiss beanspruchte Anlagen", WERKSTOFFE UND KORROSION, no. 3, 1 March 1965 (1965-03-01) - 31 March 1965 (1965-03-31), pages 185 - 189, XP002579089 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010119179A2 (fr) * 2009-04-17 2010-10-21 Metso Minerals, Inc. Procédé de préparation d'un élément de revêtement de broyeur et utilisation de cet élément
WO2010119179A3 (fr) * 2009-04-17 2010-12-16 Metso Minerals, Inc. Procédé de préparation d'un élément de revêtement de broyeur et utilisation de cet élément

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FI20086087A0 (fi) 2008-11-18
FI20086087A (fi) 2010-05-19

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