WO2015103670A1 - Élément d'usure incorporant des particules résistant à l'usure et son procédé de fabrication - Google Patents

Élément d'usure incorporant des particules résistant à l'usure et son procédé de fabrication Download PDF

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Publication number
WO2015103670A1
WO2015103670A1 PCT/AU2015/000014 AU2015000014W WO2015103670A1 WO 2015103670 A1 WO2015103670 A1 WO 2015103670A1 AU 2015000014 W AU2015000014 W AU 2015000014W WO 2015103670 A1 WO2015103670 A1 WO 2015103670A1
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WO
WIPO (PCT)
Prior art keywords
wear
particles
container
resistant member
wear particles
Prior art date
Application number
PCT/AU2015/000014
Other languages
English (en)
Inventor
Anthony Milne ROWETT
David William John Elwell
Original Assignee
Bradken Uk Limited
Bradken Resources Pty Limited
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 AU2014900068A external-priority patent/AU2014900068A0/en
Application filed by Bradken Uk Limited, Bradken Resources Pty Limited filed Critical Bradken Uk Limited
Publication of WO2015103670A1 publication Critical patent/WO2015103670A1/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
    • B22D19/02—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
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form

Definitions

  • a wear resistant member and a method for manufacturing such member is disclosed.
  • the wear resistant member may be used in many applications, for example may take the form of a wear pad, ground-engaging tool, dredge point or a mineral processing part.
  • the method may be employed in applications such as the mining industry and the disclosure is herein described in that context. However, it is to be appreciated that the disclosure is not limited to that use and may be applied to other industries that require highly abrasion resistant materials.
  • Conventional tools for use in the mining and dredge industries include wear parts that are subject to abrasion during operation of the tools and are designed to be regularly replaced.
  • the peripheral region of the ground engaging tool is exposed to extreme abrasion. This leads to rapid wear of the wear parts, which then requires replacement. Since replacement of the wear parts is interraptive to operations, it is advantageous to improve the wear performance of the parts to reduce the frequency of replacement.
  • abrasion resistant wear particles such as tungsten carbide bonded with cobalt
  • a parent matrix of metal to form the wear parts of ground engaging tools.
  • the abrasion resistant wear particles are distributed in the matrix.
  • a method of manufacturing a wear resistant member may comprise the steps of casting a combination containing liquid metal and wear particles in a mould, confining at least some of the wear particles to a region of the mould, and providing conditions suitable to harden the liquid metal to form the member with a hardened matrix, the confined wear particles forming a concentrated region of wear particles in the hardened matrix.
  • a wear resistant member is disclosed.
  • the wear resistant member may include one or more wear regions having a concentration of wear particles interspersed in the metal matrix as compared to other regions of the member.
  • Fig. 1 illustrates a process flow diagram of the method of manufacturing a wear resistant member
  • Fig. 2 illustrates a container for confining the wear resistant particles for use in the method of Fig. 1;
  • Fig. 3 illustrates a cast and hardened wear resistant member
  • Fig. 3 illustrates a section through the cast and hardened wear resistant member
  • Fig. 4 illustrates an electron image through the wear resistant member
  • Fig. 5 illustrates another electron image through the wear resistant member
  • Fig. 6 illustrates another electron image through the wear resistant member.
  • Fig. 7 illustrates another container for confining the wear resistant particles for use in sand casting.
  • the disclosure is directed generally towards ground-engaging and dredge tools for use in the mining and dredging industries, including wear parts that are subject to abrasion during operation of the tools and are designed to be regularly replaced.
  • Ground-engaging tools include teeth, adaptors and rippers for loaders, dozers, compactors, scrapers, graders and excavators. These tools are subject to rapid wear and therefore require regular replacement.
  • abrasion resistant wear particles such as tungsten carbide bonded with cobalt
  • metal such as tungsten carbide bonded with cobalt
  • tools by bonding plates to the metal surface of a tool such that it provides a protective layer of abrasion resistant wear particles.
  • the use of protective plates does increase the service life of ground engaging tools, however, they also have a number of disadvantages. Variation in the thickness of the protective coating causes irregular wear characteristics. Further, bonding protective coatings to ground engaging tools requires specialist technicians and is time consuming, which increases the overall cost of production. When casting the wear particles into a metal matrix, it is difficult to control the settled location of the wear particles. Again, this results in varied wear characteristics of ground engaging tools.
  • a method of manufacturing a wear resistant member may comprise the steps of casting a combination containing liquid metal and wear particles in a mould, confining at least some of the wear particles to a region of the mould, and providing conditions suitable to harden the liquid metal to form the member with a hardened matrix, the confined wear particles forming a concentrated region of wear particles in the hardened matrix.
  • the confined wear particles are disposed within a container.
  • the liquid metal infiltrates the container during casting.
  • the container is foraminous to allow the container to be is infiltrated by the liquid metal during casting.
  • the confined wear particles are disposed loosely within the container such that when the container is infiltrated by the liquid metal, the confined wear particles become interspersed within the liquid metal.
  • the container is a package formed from metal or ceramic such that during casting the package forms part of the hardened matrix.
  • the container is at least partly destroyed during manufacturing of the wear materials.
  • the container remains largely intact in the hardened matrix.
  • the wear particles are formed from a highly abrasion resistant material.
  • the wear particles include carbide particles with a nominal diameter of between 0.05 and 10mm. In some forms, the wear particles include ceramic particles with a nominal diameter of between 0.05 and 10mm. In some forms, the wear particles include both carbide and ceramic particles. In some forms, the container within which the wear particles are confined is located within a second container.
  • a wear resistant member having a metal matrix containing wear particles wherein the member includes one or more wear regions having a concentration of wear particles interspersed in the metal matrix as compared to other regions of the member.
  • the wear resistant member may be formed in a mould by casting.
  • the wear resistant member has an abrasion resistant face formed from a wear region of the hardened matrix.
  • the one or more wear regions are defined by one or more containers that confined the wear particles during manufacture of the member.
  • the container is foraminous to allow for liquid metal infiltration into the container during forming of the member.
  • the confined wear particles are disposed loosely within the container such that infiltration of the container by the liquid metal during casting causes the wear particles to be interspersed within the region of the matrix.
  • the container is at least partially destroyed during forming of the member so that the container forms part of the metal matrix.
  • the wear particles are formed from a highly abrasion resistant material.
  • the wear particles include carbide particles with a nominal diameter of between 0.05 and 10mm.
  • the wear particles include ceramic particles with a nominal diameter of between 0.05 and 10mm.
  • the wear particles include both carbide and ceramic particles.
  • the wear resistant member is a ground engaging tool or dredge tool.
  • a process flow chart for a method 1 of casting a wear resistant member 10 (see Fig. 3) is shown.
  • the method involves the confinement of wear particles 1 1 in the casting process so as to provide one or more regions 15 of wear particle concentrations in the member 10.
  • wear particles are introduced into a mould 21 in at least one container.
  • the container which may be in the form of an open mesh package 13 (as shown in Fig. 2), may be located in position by being located on a surface of the mould, suspended in the mould or by being placed in an outer supporting container or frame (not shown).
  • the wear particles may be in the form of tungsten carbide particles and are loosely packed in the container so as to allow infiltration by liquid metal.
  • molten metal is introduced into the mould to cast the wear member.
  • the molten metal infiltrates the container(s) and the loosely packed wear particles so that those particles are dispersed in the liquid metal (yet are still confined to the area defined by the container) so as to maintain a concentration of the wear particles.
  • step 7 conditions are provided that are suitable/conducive to harden the liquid metal to form the wear member 10 with a hardened matrix.
  • the container may be at least partially destroyed so as to form part of the member matrix or may retain its structure throughout the process.
  • the contained wear particles form a concentrated region in the hardened matrix.
  • the concentrated region of wear particles forms the region of the wear member that is highly abrasion resistant. This is a result of the region containing a relatively high concentration of wear particles. Outside this region, the matrix of the member 10 may be predominately metal and may not include a localised concentration of wear particles (see for example as shown in region 17 as shown in Fig. 3).
  • the package 13 used to confine the wear particles is as illustrated foraied from metal or ceramic and is foraminous.
  • the walls of the package 13 have an open, woven or mesh-like structure to allow the liquid metal to enter the package during casting.
  • Any foraminous structure e.g. slits, square holes, round holes
  • the foraminious structure also allows the package to become integrated in the hardened matrix, even if the package is not fully destroyed thereby reducing the likelihood of weakened regions in the resulting member.
  • the confined wear particles 1 1 are disposed loosely within the package 13. As previously mentioned this facilitates infiltration by the liquid metal during casting and ensures that the confined wear particles 11 become interspersed within the liquid metal.
  • Fig. 3 shows a cross-section of the hardened matrix of a sample cast member 10 in the mould 21.
  • a wear region 15 being formed containing the high concentration of wear particles in the hardened metal matrix and a surrounding region 17 being formed without wear particles.
  • the wear region may extend to a surface of the member to form an abrasion resistant face 19 (Fig. 3).
  • the region 15 of the hardened matrix that forms the face 19 also extends away from the face 19. Therefore, as the face 19 of the wear member breaks down / is worn during use, the newly exposed surface of the wear member becomes the abrasion resistant wear surface of the ground-engaging tool. This allows for an increased service life relative to a tool to which a protective coating or plate is applied.
  • the wear particles 11 are typically formed from a highly abrasion resistant material such as ceramic or carbide particles.
  • the wear particles are tungsten carbide, which is known to be an abrasion resistant material.
  • the volume and size of the particles is dependent on the size and application of the ground engaging tool. Usually, a higher volume fraction of hard particles is used in a small casting, whereas a relatively low volume fraction is used in a larger casting.
  • Fig. 4 shows a first electron image through the wear resistant member 10 (noting the scale showing 1mm).
  • Fig. 5 shows a greater magnified image of the matrix (noting the scale showing scale of 400 ⁇ ).
  • Figs. 4 and 5 show a clear distinction between the regions of high concentration of wear particles 15 and other regions 17 (without wear particles) can be seen.
  • the larger wear particles can be seen in combination with the small wear particles near the boundary with region 17.
  • Fig. 6 shows an even more magnified region (noting the scale showing 30 ⁇ ). In Fig. 6 the dispersion of the small wear particles in the metal matrix can be more easily seen.
  • the package 13 includes multiple compartments.
  • the compartments allow for wear particles of differing diameter to be confined to segments within the region of the mould 21.
  • the compartments may have different size holes (i.e. as large as possible while still confining the wear particles within the compartments).
  • the container is a perforated steel tube that is open ended and is inserted into the bottom of a sand casting mould typically to a depth of 50mm so that is held in the sand.
  • the tube extends into the sand as a method of location and the portion of the tube in the sand does not contain any hard particles.
  • the perforations in the steel tube are smaller in diameter relative to the wear resistant particles so as to restrain the wear particles (e.g. tungsten carbide) within the tube.
  • the tube is filled with tungsten carbide granules up to approximately 12mm of the top of the tube 37.
  • a number of these tubes may be inserted into the sand mould 39 to produce a wear surface with multiple regions of wear particle concentrations.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un élément résistant à l'usure, tel qu'un outil de binage ou un point de dragage, dans lequel des particules d'usure sont confinées à une région d'un moule dans lequel l'élément d'usure est formé par la coulée d'un métal liquide dans le moule. Le procédé peut être utilisé dans des applications telles que les industries minières et de dragage pour former un matériau hautement résistant à l'abrasion. L'invention concerne également un élément résistant à l'usure, l'élément résistant à l'usure ayant une matrice métallique contenant des particules d'usure. Les particules d'usure sont concentrées dans une région au sein de la matrice métallique durcie.
PCT/AU2015/000014 2014-01-09 2015-01-09 Élément d'usure incorporant des particules résistant à l'usure et son procédé de fabrication WO2015103670A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2014900068 2014-01-09
AU2014900068A AU2014900068A0 (en) 2014-01-09 Wear member incorporating wear resistant particles and method of making same

Publications (1)

Publication Number Publication Date
WO2015103670A1 true WO2015103670A1 (fr) 2015-07-16

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Family Applications (1)

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PCT/AU2015/000014 WO2015103670A1 (fr) 2014-01-09 2015-01-09 Élément d'usure incorporant des particules résistant à l'usure et son procédé de fabrication

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Country Link
WO (1) WO2015103670A1 (fr)

Citations (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1539919A (en) * 1975-05-24 1979-02-07 Christensen Inc Method for centrifugally casting abrasion resisting bodies
US4220455A (en) * 1978-10-24 1980-09-02 General Electric Company Polycrystalline diamond and/or cubic boron nitride body and process for making said body
JPS58119455A (ja) * 1981-12-30 1983-07-15 Kubota Ltd 耐摩耗鋳物の遠心力鋳造法
CA1192019A (fr) * 1981-04-27 1985-08-20 Nicholas Makrides Piece coulee a compacts resistants a l'usure, et sa fabrication
US4626464A (en) * 1983-04-27 1986-12-02 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Wear resistant compound body
CA2002284A1 (fr) * 1988-11-10 1990-05-10 Michael Kevork Aghajanian Methode pour le formage de composites a matrice metallique selon un procede d'infiltration spontenee; le produit ainsi obtenu
CA2081557A1 (fr) * 1990-05-09 1991-11-10 Kurt Joseph Becker Methodes de production de composites a matrice metalliques
DE4112000A1 (de) * 1991-03-23 1992-09-24 Karl Lange Verfahren zur herstellung von verschleissgeschuetzten gussstuecken
CA2081048A1 (fr) * 1991-10-23 1993-04-24 James Alexander Evert Bell Preforme de carbone a revetement nickel
CA2086868A1 (fr) * 1992-01-21 1993-07-22 Gopal Subray Revankar Rechargement en dur de surfaces metalliques a l'aide d'un materiau en feuilles resistant a l'usure
US6033791A (en) * 1997-04-04 2000-03-07 Smith And Stout Research And Development, Inc. Wear resistant, high impact, iron alloy member and method of making the same
US6079962A (en) * 1997-03-25 2000-06-27 Copeland Corporation Composite aluminum alloy scroll machine components
US7442261B2 (en) * 2000-05-16 2008-10-28 Proengco Tooling Ab Iron-base alloy containing chromium-tungsten carbide and a method of producing it
US7497280B2 (en) * 2005-01-27 2009-03-03 Baker Hughes Incorporated Abrasive-impregnated cutting structure having anisotropic wear resistance and drag bit including same
CA2732518A1 (fr) * 2008-08-22 2010-02-25 Tdy Industries, Inc. Trepans de foreuse et autres pieces incluant du carbure cemente
CA2468352C (fr) * 2001-12-04 2010-06-15 Claude Poncin Pieces de fonderie avec une resistance accrue a l'usure
US20100192475A1 (en) * 2008-08-21 2010-08-05 Stevens John H Method of making an earth-boring metal matrix rotary drill bit
US20110229715A1 (en) * 2008-09-19 2011-09-22 Magotteaux International S.A. Hierarchical composite material
US20130056139A1 (en) * 2010-04-07 2013-03-07 David Hermann Method For Producing A Cast Workpiece Having Increased Wear Protection at least in Regions
CA2860627A1 (fr) * 2012-01-31 2013-08-08 Esco Corporation Materiau resistant a l'usure et systeme et procede de creation d'un materiau resistant a l'usure
EP2650064A2 (fr) * 2012-04-10 2013-10-16 Akademia Górniczo-hutnicza Im. Stanis Awa Staszica Procédé de production de zones composites dans des pièces coulées

Patent Citations (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1539919A (en) * 1975-05-24 1979-02-07 Christensen Inc Method for centrifugally casting abrasion resisting bodies
US4220455A (en) * 1978-10-24 1980-09-02 General Electric Company Polycrystalline diamond and/or cubic boron nitride body and process for making said body
CA1192019A (fr) * 1981-04-27 1985-08-20 Nicholas Makrides Piece coulee a compacts resistants a l'usure, et sa fabrication
JPS58119455A (ja) * 1981-12-30 1983-07-15 Kubota Ltd 耐摩耗鋳物の遠心力鋳造法
US4626464A (en) * 1983-04-27 1986-12-02 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Wear resistant compound body
CA2002284A1 (fr) * 1988-11-10 1990-05-10 Michael Kevork Aghajanian Methode pour le formage de composites a matrice metallique selon un procede d'infiltration spontenee; le produit ainsi obtenu
CA2081557A1 (fr) * 1990-05-09 1991-11-10 Kurt Joseph Becker Methodes de production de composites a matrice metalliques
DE4112000A1 (de) * 1991-03-23 1992-09-24 Karl Lange Verfahren zur herstellung von verschleissgeschuetzten gussstuecken
CA2081048A1 (fr) * 1991-10-23 1993-04-24 James Alexander Evert Bell Preforme de carbone a revetement nickel
CA2086868A1 (fr) * 1992-01-21 1993-07-22 Gopal Subray Revankar Rechargement en dur de surfaces metalliques a l'aide d'un materiau en feuilles resistant a l'usure
US6079962A (en) * 1997-03-25 2000-06-27 Copeland Corporation Composite aluminum alloy scroll machine components
US6033791A (en) * 1997-04-04 2000-03-07 Smith And Stout Research And Development, Inc. Wear resistant, high impact, iron alloy member and method of making the same
US7442261B2 (en) * 2000-05-16 2008-10-28 Proengco Tooling Ab Iron-base alloy containing chromium-tungsten carbide and a method of producing it
CA2468352C (fr) * 2001-12-04 2010-06-15 Claude Poncin Pieces de fonderie avec une resistance accrue a l'usure
US7497280B2 (en) * 2005-01-27 2009-03-03 Baker Hughes Incorporated Abrasive-impregnated cutting structure having anisotropic wear resistance and drag bit including same
US20100192475A1 (en) * 2008-08-21 2010-08-05 Stevens John H Method of making an earth-boring metal matrix rotary drill bit
CA2732518A1 (fr) * 2008-08-22 2010-02-25 Tdy Industries, Inc. Trepans de foreuse et autres pieces incluant du carbure cemente
US20110229715A1 (en) * 2008-09-19 2011-09-22 Magotteaux International S.A. Hierarchical composite material
US20130056139A1 (en) * 2010-04-07 2013-03-07 David Hermann Method For Producing A Cast Workpiece Having Increased Wear Protection at least in Regions
CA2860627A1 (fr) * 2012-01-31 2013-08-08 Esco Corporation Materiau resistant a l'usure et systeme et procede de creation d'un materiau resistant a l'usure
EP2650064A2 (fr) * 2012-04-10 2013-10-16 Akademia Górniczo-hutnicza Im. Stanis Awa Staszica Procédé de production de zones composites dans des pièces coulées

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