WO2013084080A1 - Composites céramiques à matrice métallique à résistance à l'usure améliorée - Google Patents

Composites céramiques à matrice métallique à résistance à l'usure améliorée Download PDF

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Publication number
WO2013084080A1
WO2013084080A1 PCT/IB2012/052343 IB2012052343W WO2013084080A1 WO 2013084080 A1 WO2013084080 A1 WO 2013084080A1 IB 2012052343 W IB2012052343 W IB 2012052343W WO 2013084080 A1 WO2013084080 A1 WO 2013084080A1
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WO
WIPO (PCT)
Prior art keywords
ceramic
mmcc
metal matrix
alumina
grains
Prior art date
Application number
PCT/IB2012/052343
Other languages
English (en)
Inventor
Sudhir Vaman BHIDE
Original Assignee
Aia Engineering 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
Application filed by Aia Engineering Ltd. filed Critical Aia Engineering Ltd.
Publication of WO2013084080A1 publication Critical patent/WO2013084080A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/51—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal
    • C04B41/5144—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal with a composition mainly composed of one or more of the metals of the iron group
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C04B41/88—Metals
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/12—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on oxides

Definitions

  • the present invention relates to a method of manufacturing metal matrix ceramic composites with improved wear resistance ceramic form. More particularly the present invention relates to a method of manufacturing metal matrix ceramic composites for wear applications in which a body comprising alumina comprising grains is formed and said body is infiltrated with molten metal.
  • metal matrix ceramic composites MMCC
  • metal matrix ceramic composites a body comprising ceramic grains is infiltrated with molten metal to form composite.
  • MMCC Metal matrix ceramic composites
  • Mill operators make continuously increasing demands on suppliers of mill liners as the quality of material being ground deteriorates. In fact such demands spurred the development metal matrix ceramic parts. Still efforts continue to improve wear life of mill liners.
  • Metal matrix ceramic wear part production consists of making a form or a cake of ceramic grains using a suitable binder, placing the form or cake thus formed at the mold face corresponding to wearing face of wear component and pouring liquid metal in the mold.
  • the liquid metal penetrates the voids in the ceramic cake forming metal matrix composite.
  • the wear life of the metal matrix composite is a very important parameter; since the mill has to be stopped each time the wear component is worn down to replace the wear component.
  • US Patent 6,399,176 discloses a process for manufacturing of composite wear component consisting of metal matrix whose wear surface comprising inserts being made of homogenous solid solution of 20 to 80% of alumina and 80-20% of zirconia by weight. Improved wear characteristic has been tried to achieve by the process provided in this patent. This patent teaches use of only alumina and zirconia. Further, to obtain pure alumina-zirconia homogenous solid solutions challenging and a costlier process.
  • US 5,143,522 discloses abrasive grain comprising about 20 to about 50 per cent by weight of zirconia, reduced titania of 1.5 to about 10 percent in weight, carbon in an amount of 0.03 to about 0.5%> by weight, impurities not greater than 3% by weight and balance of alumina.
  • the abrasive grain of this patent has a high proportion of tetragonal zirconia.
  • US Patent 3,181,939 discloses the process of production of fused Alumina/Zirconia grains.
  • Indian patent 248740 explains production of metal matrix ceramic wear parts using alumina, zirconia and titanium oxide grains, wherein alumina is in the range of 35-65 wt%, /zirconia is in the range of 30-60 wt% and titanium oxide in the range of 1-10 wt%.
  • Use of metal matrix ceramic composite (MMCC) using Alumina/Zirconia grains is well established industrial practice. It is well known that Alumina grains are harder (Moh hardness 9) but less tough than Zirconia grains and Zirconia grains are less hard (Moh hardness 8) but more tough than alumina grains. As alumina has higher hardness than zirconia, the grains with high alumina weight percentage are more fragile.
  • the present invention discloses the method of improving wear resistance of MMCC by improving the binding between the grains and matrix.
  • the present invention aims to provide a method and metal matrix composite with improved wear life.
  • the primary object of the present invention is to provide a method for manufacturing metal matrix ceramic composite which leads to improved wear resistance and an improved wear life.
  • Yet another object of the present invention is to provide a ceramic form for use in a method of making a metal matrix ceramic wear part.
  • Figure 1 represents the grains (1) enveloped in a layer of silicate (2) as per prior art.
  • Figure 2 represents a ceramic form wherein the grains (1) are enveloped in a layer of Sodium Silicate (2) with carbon particles (3) provided.
  • Figure 3 illustrates the MMCC, grains well in contact with metal matrix.
  • Figure 3 shows MMCC as per present invention comprising grains (1), infiltrated metal matrix (4) and broken glass layer (3 '). It can be seen that the ceramic grains (1) are held by (4). It may be noted that figures are schematic in nature.
  • the present invention relates to a metal matrix ceramic composite (MMCC) with improved wear resistance comprising of ceramic form, wherein the ceramic form comprising a mixture of ceramic grains comprising alumina, at least one binder and carbon particles, wherein the said ceramic form is embedded in molten metal.
  • MMCC metal matrix ceramic composite
  • the metal matrix ceramic composite (MMCC) is manufactured by a method comprising the steps of: (i) forming a ceramic form by mixing a mixture of ceramic grains having alumina, at least one binder and carbon particles; (ii) placing the ceramic form as obtained in step (i), in a mould (iii) pouring molten metal over the ceramic form of step (ii) for infiltration of the molten metal into the ceramic form and forming the metal matrix ceramic composite (MMCC) with improved wear resistance.
  • the present invention relates to a metal matrix ceramic composite (MMCC) with improved wear resistance comprising of ceramic form, wherein the ceramic form comprising a mixture of ceramic grains comprising alumina, at least one binder and carbon particles, wherein the said ceramic form is embedded in molten metal.
  • MMCC metal matrix ceramic composite
  • metal matrix ceramic composite MMCC wherein the amount of carbon particles is between 0.5 to 3.0 % by weight of total ceramic grains comprising alumina.
  • the MMCC wherein the carbon particles have grit size in the range of 120-220.
  • the MMCC wherein a mixture of ceramic grains comprising more than 85%, preferably more than 95% alumina.
  • the MMCC wherein ceramic form comprises fine alumina powder of grit size 1000-1500
  • the MMCC wherein fine alumina powder is in the range of 0.5 to 1.5% by weight of the total ceramic grains comprising alumina.
  • the MMCC wherein the carbon particles are graphite.
  • the MMCC wherein the graphite particles are electrode grade graphite particles.
  • the metal matrix ceramic composite (MMCC) is manufactured by the method comprising the steps of: (i) forming a ceramic form by mixing a mixture of ceramic grains having alumina, at least one binder and carbon particles; (ii) placing the ceramic form as obtained in step (i), in a mould (iii)pouring molten metal over the ceramic form of step (ii) for infiltration of the molten metal into the ceramic form and forming the metal matrix ceramic composite (MMCC) with improved wear resistance.
  • the method of manufacturing MMCC wherein the amount of carbon particles is between 0.5 to 3.0 % by weight of total ceramic grains comprising alumina.
  • the method of manufacturing MMCC wherein the carbon particles have grit size in the range of 120-220.
  • the method of manufacturing MMCC wherein a mixture of ceramic grains comprising more than 85%, preferably more than 95% alumina.
  • ceramic form comprises fine alumina powder of grit size 1000-1500
  • fine alumina powder is in the range of 0.5 to 1.5% by weight of the total ceramic grains comprising alumina.
  • the method of manufacturing MMCC wherein the carbon particles are graphite particles.
  • the method of manufacturing MMCC, wherein the graphite particles are electrode grade graphite particles.
  • the metal matrix ceramic composite is manufactured by the method comprising the steps of: (i) a mixture is formed comprising at least the following ingredients: (a) ceramic grains comprising alumina, (b) a binder and (c) carbon particles having a grit size preferably 120-220, (ii)
  • the mixture is filled in synthetic rubber core boxes and the core boxes with the mixture are baked. After the baking operation, rubber core boxes are separated to get ceramic form.
  • the ceramic form is fixed at the mold surface corresponding to the wearing surface of the casting. Construction of the ceramic form allows good infiltration by the liquid metal (iii) molten metal like iron or steel of suitable composition is poured over the ceramic form for infiltration of the molten metal into the form for forming the metal matrix ceramic composite .
  • Manufacturing process of metal matrix ceramic parts involves production of ceramic forms/cakes.
  • Sodium silicate is usually used as binder of the grains. After pouring of liquid metal, the metal infiltrates the pores in the ceramic form to form the metal matrix ceramic composite.
  • the binder usually Sodium silicate, forms a surface layer of glass on the grains. This glass layer cannot help to limit fragility of Alumina comprising grains. The grains would perform better if the grains can be more rigidly held by the metal matrix.
  • the present invention is particularly advantageous when the total alumina content in the cake is more than 85% and preferably more than 95%.
  • Wear life of MMCC can be improved if harder grains can be used.
  • Alumina grains are harder than alumina/zirconia grains but more fragile.
  • the new grains improve wear life of MMCC substantially.
  • the use of carbon particles provides for the possibility of using high alumina grains thus further improving life time.
  • the invention is thus particularly advantageous when total alumina content in the cake is more than 85% and preferably more than 95%.
  • Use of nearly pure Alumina grains in combination with the use of carbon particles provides stronger binding of alumina grains by metal matrix.
  • the carbon particles provide a mechanism of breaking silicate glass barrier between metal and ceramic grains.
  • a compatible buffer is provided between metal and ceramic grains to allow differential expansion.
  • the amount of powder carbon particles is preferably between 0.5 to 3.0 % of total alumina comprising ceramic grains in weight percentage.
  • Preferably fine alumina powder with a grit size of between 1000 - 1500 grit size is used in the mixture, preferably in a weight percentage of between 0.5 to 1.5% of total alumina comprising ceramic grains.
  • the life time is improved by improving the binding of the alumina comprising grains to the metal matrix.
  • the inventor has considered using an agent to develop stronger binding between ceramic grains and metal matrix.
  • the selected material should preferably satisfy the following criteria:
  • the agent preferably is compatible with liquid metal
  • the agent preferably withstands temperature up to 1500 0 C
  • the agent preferably has good thermal conductivity
  • Carbon particles to be employed was a further feature considered by inventor. Carbon particles are preferably in the size range of grit sizes 120 to 220.
  • the invention has a positive effect when using various alumina comprising grains, including alumina/zirconia ceramic grains, for instance comprising up to 15% zirconia.
  • alumina/zirconia ceramic grains for instance comprising up to 15% zirconia.
  • a further consideration, for a preferred embodiment of the invention, is the choice of alumina comprising grains.
  • alumina grains in the grit size range of 6 to 12 are used.
  • the grains may contain up to 5% MgO and other impurities.
  • alumina grains comprising 95% or more alumina.
  • Use of 95% or higher purity Alumina grains in combination with the use of carbon particles provides alumina grains rigidly bound and held by metal matrix.
  • the carbon particles provide a mechanism of breaking silicate glass barrier between metal and ceramic grains.
  • the carbon is absorbed in the surrounding metal matrix.
  • a compatible buffer is provided between metal and ceramic grains to allow differential expansion.
  • Fine Aluminum oxide powder is added in the range of grit sizes 1000 - 1500 to improve moldability.
  • a mixture of Alumina grains containing at least 85 %, preferably at least 95% AI 2 O 3 by weight, balance being impurities like Magnesium oxide (MgO) and others, size range of particles being 6 to 12 grit sizes.
  • the mixture in embodiments is more or less homogeneous mixture, i.e.
  • EGG electrode grade graphite
  • EGG electrode grade graphite
  • Other types of soft carbon that could be used are types of carbons such as charcoal, coal (anthracite, lignite etc), carbon black and soot.
  • Graphite is preferred for its purity over such other types of soft carbons.
  • Fine Alumina powder in the range of grit sizes 1000 - 1500. Fine Alumina powder is added between 0.5 to 1.5% of total ceramic particles.
  • the method is not restricted to any manner as to how the ingredients are mixed, in particularly not with respect as to the order in which ingredients of the mixture are added to the mixture.
  • the first step in forming a Metal Matrix Ceramic Composite (MMCC) wear part is formation of cake/form.
  • Ceramic ingredients as above, are mixed with a suitable binder, specifically Sodium Silicate.
  • the binder is preferably added to the extent of approximately 5% by weight.
  • the mixture is poured in rubber core boxes having shape that will give ceramic cake of desired shape and size.
  • Carbon Dioxide gas is passed over the filled box to develop adequate strength for handling.
  • Ceramic form with rubber core box is baked for example between 100 and 225 C, preferably between 100 to 125 C, for 2 to 4 hours.
  • the cakes are stripped from core boxes and are ready for use.
  • the temperature range between 100 and 125 C is preferred. Compared to using a temperature above 125 C, the risk of that carbon particles react with oxygen in oven atmosphere and getting damaged is reduced. Molds are produced using standard foundry practices. Ceramic cakes are located at surfaces of molds corresponding to wear surfaces of castings being produced. Liquid metal composition is chosen taking in to account impact conditions of application. Both iron and
  • Iron composition may contain alloying in the following range:- C 1 to 3.5%, Cr 11 to 28%, with required alloy additions such as Mo, Ni, and Cu
  • Steel composition may contain alloying in the following range:-
  • Liquid metal is poured in the molds and after allowing adequate cooling time the molds are disturbed. Castings have integral MMCC portion.
  • EXAMPLE 1 An experiment was performed on a hammer mill used to crush limestone.
  • Metal Matrix Ceramic Composite (MMCC) wear parts were produced using technology as per the present invention. Steel with 0.42% C, 3.2% Cr, 0.53% Mo, 0.37% Ni, 0.75% Mn, 0.66%) Si composition was used. The experiment showed 35% improvement in lifetime of the wear part over conventionally manufactured MMCC, i.e. without addition of carbon particles (graphite powder), MMCC wear parts comprising alumina/zirconia (in the ratio of approximately 60/40%) grains in the same mill.
  • MMCC wear parts were produced using technology as per the present invention. Cast iron with composition 2.88% C, 29.32% Cr, 0.42% Mo, 0.62% Mn, 0.81% Si was maintained. The experiment showed 27% improvement in lifetime of the wear part over conventionally manufactured MMCC wear parts comprising alumina/zirconia in the mentioned ratio in the same mill.
  • the results shows substantial improvement compared to using conventional alumina-zirconia grains.
  • using alumina grains has an advantage that alumina grains are manufactured in a manner which is less taxing to the environment, in particular less energy and resources are needed to produce alumina grains as compared to alumina/zirconia grains.
  • the above embodiment of the invention in which alumina grains are used with a very high (above 85%, preferably above 95%) percentage of alumina has the added advantage, as compared to using conventional alumina/zirconia ceramic grains, that the environment is less taxed.
  • the FEPA standard specifies the mean sizes associated with the mentioned grit sizes as follows:

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Metallurgy (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

La présente invention concerne un composite céramique à matrice métallique (MMCC) à résistance à l'usure améliorée, comprenant une forme céramique, la forme céramique comprenant un mélange de grains céramiques comprenant de l'alumine, au moins un liant et des particules de carbone, ladite forme céramique étant incorporée dans un métal fondu. La présente invention concerne également un procédé de fabrication du composite céramique à matrice métallique (MMCC) à résistance à l'usure améliorée.
PCT/IB2012/052343 2011-12-09 2012-05-11 Composites céramiques à matrice métallique à résistance à l'usure améliorée WO2013084080A1 (fr)

Applications Claiming Priority (2)

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IN3479MU2011 2011-12-09
IN3479/MUM/2011 2011-12-09

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WO2013084080A1 true WO2013084080A1 (fr) 2013-06-13

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015063785A1 (fr) * 2013-11-01 2015-05-07 Bajali Industrial Products Ltd. Composition résistante à l'usure pour la fabrication d'un composant résistant à l'usure utilisé pour la fabrication de cylindres de broyage ou de revêtements de table pour broyeurs à cylindres verticaux et son procédé de fabrication
CN105964984A (zh) * 2016-05-18 2016-09-28 四川九鼎智远知识产权运营有限公司 一种具有外强内韧结构的夯锤锤头制备工艺

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3181939A (en) 1961-01-27 1965-05-04 Norton Co Fused alumina-zirconia abrasives
US5061665A (en) 1989-01-13 1991-10-29 The Japan Carlit Co., Ltd. Process for producing an improved alumina-zirconia composite sintered material
US5143522A (en) 1979-11-09 1992-09-01 Washington Mills Electro Minerals Corporation Abrasive products containing fused alumina zirconia and reduced titania
US5551963A (en) 1992-09-25 1996-09-03 Minnesota Mining And Manufacturing Co. Abrasive grain containing alumina and zirconia
EP1059133A1 (fr) * 1999-06-11 2000-12-13 Nichias Corporation Matériau composite à matrice métallique et bloc cylindre ainsi obtenu
US6399176B1 (en) 1996-10-01 2002-06-04 Magotteaux International S.A. Composite wear component
US20080102300A1 (en) * 2006-11-01 2008-05-01 Aia Engineering, Ltd. Wear-resistant metal matrix ceramic composite parts and methods of manufacturing thereof

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3181939A (en) 1961-01-27 1965-05-04 Norton Co Fused alumina-zirconia abrasives
US5143522A (en) 1979-11-09 1992-09-01 Washington Mills Electro Minerals Corporation Abrasive products containing fused alumina zirconia and reduced titania
US5143522B1 (en) 1979-11-09 1998-01-06 Washington Mills Electro Miner Abrasive products containing fused alumina zirconia and reduced titania
US5061665A (en) 1989-01-13 1991-10-29 The Japan Carlit Co., Ltd. Process for producing an improved alumina-zirconia composite sintered material
US5551963A (en) 1992-09-25 1996-09-03 Minnesota Mining And Manufacturing Co. Abrasive grain containing alumina and zirconia
US6399176B1 (en) 1996-10-01 2002-06-04 Magotteaux International S.A. Composite wear component
EP1059133A1 (fr) * 1999-06-11 2000-12-13 Nichias Corporation Matériau composite à matrice métallique et bloc cylindre ainsi obtenu
US20080102300A1 (en) * 2006-11-01 2008-05-01 Aia Engineering, Ltd. Wear-resistant metal matrix ceramic composite parts and methods of manufacturing thereof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015063785A1 (fr) * 2013-11-01 2015-05-07 Bajali Industrial Products Ltd. Composition résistante à l'usure pour la fabrication d'un composant résistant à l'usure utilisé pour la fabrication de cylindres de broyage ou de revêtements de table pour broyeurs à cylindres verticaux et son procédé de fabrication
AU2014343170B2 (en) * 2013-11-01 2016-11-10 Bajali Industrial Products Ltd. A wear resistant composition for manufacturing wear resistant component used for making grinding roll or table liner for vertical roller mill and method to manufacture the same
CN105964984A (zh) * 2016-05-18 2016-09-28 四川九鼎智远知识产权运营有限公司 一种具有外强内韧结构的夯锤锤头制备工艺

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