WO2020237957A1 - 一种刀具涂层的加工方法 - Google Patents

一种刀具涂层的加工方法 Download PDF

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Publication number
WO2020237957A1
WO2020237957A1 PCT/CN2019/109401 CN2019109401W WO2020237957A1 WO 2020237957 A1 WO2020237957 A1 WO 2020237957A1 CN 2019109401 W CN2019109401 W CN 2019109401W WO 2020237957 A1 WO2020237957 A1 WO 2020237957A1
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Prior art keywords
phase
tool
coating
powder feeding
cladding
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PCT/CN2019/109401
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English (en)
French (fr)
Inventor
张瑞华
路超
屈岳波
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阳江市五金刀剪产业技术研究院
阳江市高功率激光应用实验室有限公司
阳江市普瑞德增材制造研究院有限公司
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Application filed by 阳江市五金刀剪产业技术研究院, 阳江市高功率激光应用实验室有限公司, 阳江市普瑞德增材制造研究院有限公司 filed Critical 阳江市五金刀剪产业技术研究院
Priority to US17/614,824 priority Critical patent/US20220243314A1/en
Priority to EP19930462.7A priority patent/EP3978648A4/en
Publication of WO2020237957A1 publication Critical patent/WO2020237957A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/106—Coating with metal alloys or metal elements only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys

Definitions

  • the invention relates to a method for processing tool coating, and belongs to the technical field of material processing.
  • the commonly used methods for preparing surface composite coatings include electroplating, surface surfacing, vapor deposition, spraying, laser cladding, and plasma cladding.
  • tungsten carbide, titanium carbide, vanadium carbide and other high-hardness carbides or nitrides are often added in the process of preparing the coating.
  • the base powder and the finer hard particles are uniformly mixed through a ball milling process, and then the coating is prepared.
  • complex solid-phase reactions occur during the ball milling and mixing of the base powder and the hard phase particles.
  • the mechanical force (shear force, impact force, etc.) generated during the ball milling process can make the metal powder/hard particles plastic Deformation, fracture, fragmentation, crystal structure reconstruction and other changes, so the ball milling process changes the initial morphology and structural characteristics of the original powder material, these changes have an unpredictable impact on the subsequent coating preparation process.
  • finer and irregular hard particles are used for separate powder feeding, it is easy to cause the problem of clogging of the powder feeding pipe; when the hard phase particles with a larger particle size are used for separate powder feeding to prepare the coating, there is The hard phase with larger particle size is easy to peel off in the coating.
  • the hard phase particles are usually mixed with the base powder and sent into a heat source for heating at the same time. In this way, under the action of a higher temperature heat source, part of the hard particles will be burnt, resulting in hard The waste of mass phase particles, and the actual performance of the prepared coating is not as good as expected.
  • the selection of hard phase particles is also a key link: the existing hard phase selection does not consider the density difference between the hard phase particles and the basic powder material, which often causes the hard phase particles to be coated Uneven distribution in the layer and cracks in the coating affect the performance of the coating.
  • the purpose of the present invention is to provide a method for processing tool coating, which solves the problem of feeding of hard phase particles, burning problems and problems in the process of tool coating processing.
  • the problem of uneven distribution in the coating improves the hardness, corrosion resistance and wear resistance of the tool coating, and ultimately increases the service life of the tool.
  • a method for processing tool coatings including:
  • Molten pool formation step converge the bonding phase to the plasma arc heat source through the coaxial powder feeding channel, and deposit the bonding phase on the tool substrate after melting to form a molten pool;
  • Reinforcement phase addition step The reinforcement phase is sent into the molten pool after the plasma beam is removed through the side shaft powder feeding channel, and the bonding phase and the reinforcement phase are cladding under the condition of ultrasonic vibration to form a coating on the surface of the tool .
  • the binder phase is a self-fluxing alloy powder
  • the binder phase density is 6-9 g/cm 3
  • the powder particle size is 48-250 ⁇ m.
  • the binder phase density referred to here refers to the density of the bulk material corresponding to the powder material, not the bulk density or tap density of the powder material.
  • the self-fluxing alloy powder is selected from one or more of stainless steel, nickel-based alloy, and cobalt-based alloy;
  • the stainless steel is selected from one or more of 1Cr13, 3Cr13, 304, 316, 420, 440, RWL34, PMC27, 5Cr15MoV, 8Cr13MoV, and 9Cr18MoV;
  • the nickel-based alloy is selected from one or more of Ni60, Ni60A, Ni60W, Ni55, Ni62, and Deloro60;
  • the cobalt-based alloy is selected from one or more of Co190, CoCrMo, Co800, Tribaloy 800, and Stellite20;
  • the self-fluxing alloy powder is selected from one or more of 3Cr13, Ni60A, CoCrMo, and 8Cr13MoV.
  • the density of the reinforcing phase is 6.1-9.2 g/cm 3 . This density is very close to the density of the binder phase.
  • the reinforcing phase referred to here is the density of the bulk material corresponding to the powder material, rather than the bulk density or tap density of the powder material.
  • the reinforcing phase includes at least one of zirconium carbide, niobium carbide, niobium nitride, zirconium nitride, and niobium boride; the reinforcing phase is spherical particles with a particle size of 5-25 ⁇ m, and the Hall flow rate is less than 25 s /50g; preferably less than 18s/50g.
  • Zirconium carbide, niobium carbide, niobium nitride, zirconium nitride and niobium boride are all of high hardness, high melting point, and similar density and bonding.
  • the density range is 6.1-9.2g/cm 3 , and the similar density can effectively prevent
  • the reinforcing phase is unevenly distributed in the coating.
  • tungsten carbide is often used as the reinforcing phase due to its high hardness.
  • tungsten carbide is deposited on the lower layer of the molten pool. , Resulting in uneven distribution and poor wear resistance of the coating surface.
  • the power of ultrasonic vibration is 50-300W.
  • the mass ratio of the binder phase and the reinforcing phase is 20: (1-50).
  • the mass ratio of the binder phase and the reinforcing phase is 12: (3-28).
  • the mass ratio of the binder phase and the reinforcing phase is 35: (15-35).
  • the base material of the cutter is selected from one or more of carbon steel and stainless steel;
  • the tool substrate is selected from one or more of No. 45 carbon steel, carbon steel Q235, 2Cr13 stainless steel, 3Cr13 stainless steel, 5Cr15 stainless steel, and 304 stainless steel.
  • the tool base material is 3Cr13
  • the binder phase is 3Cr13
  • the reinforcing phase is niobium carbide.
  • the tool base material is 45# carbon steel
  • the binder phase is Ni60A nickel-based alloy powder
  • the reinforcing phase is zirconium carbide.
  • the tool substrate is 304 stainless steel
  • the binder phase is CoCrMo cobalt-based alloy powder
  • the reinforcing phase is niobium boride.
  • the tool base material is 5Cr15 stainless steel
  • the binder phase is 8Cr13MoV iron-based alloy powder
  • the reinforcing phase is niobium nitride.
  • the angle between the central axis of the coaxial powder feeding channel and the side shaft powder feeding channel is 15-75 degrees.
  • the distance between the discharge nozzle of the coaxial powder feeding channel and the cutter substrate is 5-15 mm, and the feeding speed of the binder phase is 10-25 g/min.
  • the horizontal distance between the discharge nozzle of the lateral powder feeding channel and the discharge nozzle of the coaxial powder feeding channel is 1-5 cm, and the feeding speed of the reinforcing phase is 5-14 g/min.
  • the plasma beam arc is a combined plasma arc
  • the cladding conditions are: ion gas flow 0.6-6L/min, protective gas flow 5-25L/min, powder feeding gas flow 0.6-6L/min, cladding current 3-180A, base value/start arc current 0-29A, arc current 0-20A, cladding time 50-300ms, interval time 50-300ms, protective gas delay 0-5s, current rise time and fall time are both 0.1-0.5s, protective gas advance 0-3s, cladding speed 120-480mm/min.
  • the cladding conditions are: ion gas flow 3-5L/min, protective gas flow 5-10L/min, powder feeding gas flow rate 2-5L/min, cladding current 20-50A, base value/start arc current 20-29A, arc current 5-10A, cladding time 80-150ms, interval time 50-150ms, protective gas delay 1-3s, current rise time and fall time are both 0.1-0.5s, protective gas advance 0-3s, cladding speed 150-300mm/min.
  • the processing method further includes annealing, quenching, and tempering heat treatment on the tool coating.
  • the invention uses coaxial powder feeding combined with lateral shaft powder feeding to reduce the burning of the reinforcing phase due to excessively high temperature; the invention avoids the method of mixing the reinforcing phase and the binder phase through ball milling, because This method will destroy the morphology and surface energy of the raw materials during the ball milling process, and then affect the cladding process and performance.
  • the side shaft powder feeding pipeline is used to send the reinforcing phase directly into the molten pool instead of the heat source plasma arc, which can also reduce the burning loss caused by directly feeding the heat source;
  • the addition of ultrasonic vibration has a significant effect on the flow of the molten pool metal after cladding, the nucleation of crystals and the growth of crystal grains.
  • the growing crystal grains are under ultrasonic vibration. Broken to form multiple nucleation cores, increase the nucleation rate, and finally form a coating with fine grains.
  • the ultrasonic vibration has a good auxiliary effect on the uniform distribution of the hard phase particles in the coating, and the blade part is prepared without cracks.
  • Figure 1 is a schematic diagram of the processing in Example 1;
  • Figure 2 shows the surface morphology of the tool in Example 1 after the cutting edge
  • Figure 3 is a metallographic photo of the tool in Example 1 after cutting its edge
  • Figure 4 is the surface morphology of the tool in Example 2 after the cutting edge
  • Figure 5 is a metallographic photo of the tool in Example 2 after cutting its edge
  • Figure 6 is the surface morphology of the tool in Example 3 after the cutting edge
  • Figure 7 is a metallographic photo of the tool in Example 3 after the cutting edge
  • Figure 8 is the surface morphology of the tool in Example 4 after the cutting edge
  • Figure 9 is a metallographic photo of the tool in Example 4 after the cutting edge
  • Figure 10 is the surface morphology of the cutting tool in Example 5.
  • Figure 11 is a metallographic photo of the tool in Example 5 after the cutting edge
  • Figure 12 is the surface morphology of the tool in Example 6 after cutting
  • Figure 13 is a metallographic photo of the tool in Example 6 after the cutting edge
  • Figure 14 shows the macroscopic crack morphology of the coating of Comparative Example 3.
  • Figure 15 is a metallographic photo of the tool in Comparative Example 5 after sharpening
  • Figure 16 is a picture of the corrosion morphology of Comparative Example 5.
  • Figure 17 is a metallographic photo of the corrosion pit of Comparative Example 5.
  • Figure 18 is a metallographic photo of the coating of Comparative Example 6;
  • a method for processing tool coating including:
  • Molten pool formation steps Converge the bonding phase to the plasma arc heat source through the coaxial powder feeding channel, and deposit the bonding phase on the tool base material after melting to form a molten pool;
  • the bonding phase is self-fluxing alloy powder with a powder density of 6 -9g/cm 3 , the powder particle size is 48-250 ⁇ m;
  • the particle size of the binder phase is limited to 48-250 ⁇ m to overcome the problem of powder feeding clogging;
  • the distance between the discharge nozzle of the coaxial powder feeding channel and the tool substrate is 5-15mm.
  • Reinforcement phase addition step send the reinforcement phase into the molten pool after the plasma beam is removed through the side axis powder feeding channel, and cladding the bonding phase and the reinforcement phase under the condition of ultrasonic vibration power of 50-300W. Coating is formed on the surface of the tool;
  • the horizontal distance between the discharge nozzle of the side shaft powder feeding channel and the discharge nozzle of the coaxial powder feeding channel is 1-5 cm.
  • the reinforcing phase includes at least one of zirconium carbide, niobium carbide, niobium nitride, zirconium nitride and niobium boride; the reinforcing phase is spherical particles with a particle size of 5-25 ⁇ m, and the Hall flow rate is less than 25s/50g; preferably less than 18s /50g;
  • the powder density of the binder phase is limited to 6-9g/cm 3
  • the reinforcing phase materials are zirconium carbide, niobium carbide, niobium nitride and niobium boride, all of which have high hardness and high melting point, and the density is similar to that of the binder phase. It is 6.1-9.2g/cm 3 , and the density is similar, which can effectively prevent the uneven distribution of the reinforcing phase in the coating.
  • Traditional cladding technology does not consider the relationship between the density of the reinforcement phase and the density of the binding phase when selecting the reinforcement phase, which is likely to cause the reinforcement phase to be unevenly distributed in the coating due to the density difference in the molten pool, which affects the coating. Uniformity of layer performance;
  • the particle size of 5-25 ⁇ m can not only ensure the smooth delivery of the reinforcing phase, but also prevent the coating from falling off during the later polishing process.
  • the particle size is small, the fine particles are easy to agglomerate under the action of van der Waals force and moisture, causing the blockage of the pipeline during the powder feeding process;
  • the particle size is large, although the lateral axis powder feeding is easier to achieve, the coating is sharpened in the later stage It is easy to cause the reinforcement phase particles to fall off during the grinding process;
  • the reinforcing phase is spherical and the Hall flow rate is small, which can ensure the smooth feeding of the reinforcing phase into the molten pool; when the reinforcing phase is non-spherical, the friction between the particles is large, the flow performance is poor, and the Hall flow rate time It is longer, which eventually leads to difficulty in powder feeding; the present invention uses spherical powder, which has good flow properties and can realize side-axis powder feeding;
  • the bonding phase first interacts with the micro-plasma heat source to create a molten pool on the substrate. After the plasma beam is removed, the molten pool is solidified, and after the reinforcing phase is fed into the molten pool, the ultrasonic vibration can make the reinforcing phase melt The distribution in the pool is more even.
  • the mass ratio of the binder phase and the reinforcing phase is 20:(1-50); preferably 12:(3-28); more preferably 35:(15-35).
  • the reinforcing phase plays the role of improving hardness and wear resistance in the binding phase, and evenly distributed in the coating can achieve the effect of soft and hard combination, and finally increase the hardness and wear resistance of the coating; but when the content of the reinforcing phase is too small, the strengthening effect Not obvious; when the content of the reinforcing phase is too much, the binder phase decreases accordingly.
  • the front of the solidification interface cannot be supplemented by the melt and macroscopic cracks appear.
  • the angle between the central axis of the coaxial powder feeding channel and the side shaft powder feeding channel is 15-75 degrees;
  • This angle range can ensure that the cladding coating has a good appearance, and the angle between the outlet nozzle of the side-axis powder feeding channel and the outlet nozzle of the coaxial powder feeding channel cannot be too large or too small, otherwise it will affect The appearance of the cladding coating.
  • the plasma beam arc is a combined plasma arc
  • the non-transferred arc and the transferred arc work at the same time.
  • the function of the non-transferred arc is to start the arc and maintain the arc, so that the transferred arc can work stably under a small current.
  • the transfer arc is used to melt powder.
  • the combined plasma arc has arc stability and energy. The advantages of high density and wide processing technology window.
  • the cladding conditions are: ion air flow 0.6-6L/min, protective air flow 5-25L/min, powder feeding air flow 0.6-6L/min, cladding current 3-180A, base value/ignition arc current 0-29A, dimension Arc current is 0-20A, cladding time 50-300ms, interval time 50-300ms, protective gas delay 0-5s, current rise time and fall time are both 0.1-0.5s, protective gas advance 0-3s, cladding Speed 120-480mm/min; argon gas is used for shielding gas, ion gas and powder feeding gas.
  • the cladding conditions are: ion air flow 3-5L/min, protective air flow 5-10L/min, powder feeding air flow rate 2-5L/min, cladding current 20-50A, base value/start arc current 20 -29A, the arc current is 5-10A, the cladding time is 80-150ms, the interval time is 50-150ms, the protective gas delay is 1-3s, the current rise time and fall time are both 0.1-0.5s, the protective gas advances 0- 3s, cladding speed 150-300mm/min.
  • the prepared tool coating is subjected to corresponding annealing and stress relief treatment, and then corresponding quenching and tempering heat treatment.
  • Figure 1 shows the schematic diagram of the processing.
  • the cohesive phase 1 feeds powder from the coaxial powder feeding channel, and the reinforced phase 2 feeds powder from the side axis powder feed channel.
  • a method for processing tool coating including:
  • Molten pool formation steps Converge the bonding phase in the plasma arc heat source through the coaxial powder feeding channel, the bonding phase is melted and deposited on the tool base material (3Cr13) to form a molten pool;
  • the bonding phase is stainless steel 3Cr13 (density 7.75g/ cm 3 ), the powder particle size is 53-105 ⁇ m; the distance between the discharge nozzle of the coaxial powder feeding channel and the tool substrate is 8mm, and the feeding speed of the binder phase is 10g/min;
  • Reinforcement phase addition step send the reinforcement phase into the molten pool after the plasma beam is removed through the side axis powder feeding channel, the reinforcement phase is niobium carbide with a density of 7.8g/cm 3 ; the reinforcement phase is spherical particles with a particle size of 5- 20 ⁇ m, Hall flow rate 17.5s/50g; the horizontal distance between the outlet nozzle of the side-axis powder feeding channel and the outlet nozzle of the coaxial powder feeding channel is 1cm, and the feeding speed of the reinforcing phase is 6g/min; Under the condition of ultrasonic vibration power of 100W, cladding the bonding phase and the reinforcing phase to form a coating on the surface of the tool;
  • the mass ratio of the binder phase and the reinforcing phase is 19:1;
  • the angle between the central axis of the coaxial powder feeding channel and the side shaft powder feeding channel is 45 degrees;
  • the plasma beam arc is a combined plasma arc
  • the cladding conditions are: ion airflow 3L/min, protective airflow 6L/min, powder feeding air flow 3L/min, cladding current 30A, base/strike arc current 28A, vertical arc current 10A, cladding time 100ms, The interval time is 100ms, the protective gas delay is 3s, the current rise time and fall time are both 0.1s, the protective gas advances 2s, and the cladding speed is 240mm/min; the protective gas, ion gas, and powder feeding gas are all argon.
  • Figure 2 is the surface morphology of the tool after the coating is finished, and there is no corrosion spots on the blade;
  • Figure 3 is the metallographic photo after the blade is smooth, the blade is smooth and defect-free, indicating that the reinforcing phase particles are bonding It has a good strengthening effect in the phase, and does not affect the corrosion of the coating and the sharpening of the edge.
  • Example 1 The difference from Example 1 is that the ratio of the mass of the binder phase and the reinforcing phase is 3:2;
  • the particle size of the binder phase is 105-180 ⁇ m; the particle size of the reinforcing phase is 10-25 ⁇ m, and the Hall flow rate is 17s/50g; the remaining processing parameters are the same as in Example 1.
  • Example 1 The difference from Example 1 is that the ratio of the mass of the binder phase and the reinforcing phase is 3:7;
  • the particle size of the binder phase is 120-200 ⁇ m; the particle size of the reinforcing phase is 15-25 ⁇ m, and the Hall flow rate is 16.5s/50g; other processing parameters are the same as in Example 1.
  • the surface morphology and metallographic picture of the tool after the cutting edge are shown in Figure 6-7.
  • the surface morphology has no corrosion phenomenon and the phenomenon of particle shedding of the reinforcing phase.
  • Example 1 The difference from Example 1 is that the base material in this example is 5Cr15 stainless steel, the binder phase is 8Cr13MoV iron-based alloy powder, the binder phase density is 7.82g/cm3, the powder particle size is 120-250 ⁇ m, and the coaxial powder feeding
  • the distance between the discharge nozzle of the channel and the tool substrate is 10mm;
  • the reinforcing phase is spherical niobium nitride with a density of 7.3g/cm3, the particle size is 8-25 ⁇ m, and the Hall flow rate is 20.0s/50g;
  • the side axis powder feeding channel The horizontal distance between the material nozzle and the discharge nozzle of the coaxial powder feeding channel is 3cm; and the bonding phase and the reinforcing phase are cladding under the condition of an ultrasonic vibration power of 200W, using the same method as in Example 1 and The same process parameters form a coating on the surface of the tool;
  • the mass ratio of the binder phase and the reinforcing phase is 1:1;
  • the angle between the central axis of the coaxial powder feeding channel and the side shaft powder feeding channel is 60 degrees;
  • the prepared tool coating is quenched at 1080°C/30min and cooled to room temperature in air; then tempered at 500°C/30min and cooled to room temperature in air.
  • the surface morphology and metallographic pictures of the cutting tool are shown in Figure 8-9, and the surface morphology has no corrosion phenomenon and the phenomenon of reinforcing phase particles falling off.
  • Example 2 The difference from Example 1 is that the base material in this example is 304 stainless steel, the binder phase is CoCrMo cobalt-based alloy powder, the binder phase density is 8.53 g/cm 3 , and the powder particle size is 120-200 ⁇ m.
  • the distance between the discharge nozzle of the powder channel and the tool substrate is 13mm; the reinforcing phase is spherical niobium boride with a density of 7.2g/cm 3 , the particle size is 5-15 ⁇ m, and the Hall flow rate is 22.8s/50g; the side axis powder feeding channel
  • the horizontal distance between the discharging nozzle and the discharging nozzle of the coaxial powder feeding channel is 5cm; and the bonding phase and the reinforcing phase are cladding under the condition of the ultrasonic vibration power of 150W, using the same as in Example 1. Method and the same process parameters to form a coating on the surface of the tool;
  • the mass ratio of the binder phase and the reinforcing phase is 3:7;
  • the angle between the central axis of the coaxial powder feeding channel and the side shaft powder feeding channel is 70 degrees;
  • the prepared tool coating was solution treated at 1100°C/60min, and then air-cooled to room temperature.
  • the surface morphology and metallographic pictures of the tool after the cutting edge are shown in Figure 10-11.
  • the surface morphology has no corrosion phenomenon and the phenomenon of particle shedding of the reinforcing phase.
  • Example 1 The difference from Example 1 is that the base material in this example is 45# carbon steel, the binder phase is Ni60A nickel-based alloy powder, the binder phase density is 7.53g/cm 3 , and the powder particle size is 105-180 ⁇ m.
  • the distance between the discharge nozzle of the axial powder feeding channel and the tool substrate is 10mm; the reinforcement phase is spherical zirconium carbide with a density of 6.4g/cm 3 , the particle size is 10-25 ⁇ m, and the Hall flow rate is 19s/50g; the lateral axial powder feeding channel
  • the horizontal distance between the discharging nozzle and the discharging nozzle of the coaxial powder feeding channel is 2cm; and the bonding phase and the reinforcing phase are cladding under the condition of ultrasonic vibration power of 120W, using the same method as in Example 1. Method and the same process parameters to form a coating on the surface of the tool;
  • the mass ratio of the binder phase and the reinforcing phase is 3:2;
  • the angle between the central axis of the coaxial powder feeding channel and the side shaft powder feeding channel is 60 degrees;
  • the surface morphology and metallographic pictures of the tool after the cutting edge are shown in Figure 12-13.
  • the surface morphology has no corrosion phenomenon and the phenomenon of particle shedding of the reinforcing phase.
  • the mass ratio of binder phase and reinforcing phase is 19:1;
  • the particle size of the binder phase is 53-105 ⁇ m; the particle size of the reinforcing phase is 5-20 ⁇ m, and the Hall flow rate is 17.5s/50g; Comparative Example 1 uses a ball mill to mix the reinforcing phase and the binder phase, and the mixed powder uses plasma cladding. Shaft powder feeding, instead of coaxial and side shaft mixed powder feeding, other processing parameters are the same as in Example 1.
  • the reinforcing phase is fed directly under the heat source and is directly heated by the plasma of the heat source, which will cause a certain amount of burning loss.
  • the structure of the reinforcing phase will be changed when ball milled, and the overall result will cause the coating performance to decrease and friction Poor performance.
  • the mass ratio of the binder phase and the reinforcing phase is 97:3; other processing parameters are the same as in Example 1.
  • the content of the reinforcing phase is less. Therefore, the overall performance of the coating is lower than that of Example 1, but the performance is similar to that of Comparative Example 1, further confirming that the ball-milled mixed powder and the burning loss of the reinforcing phase have a certain effect on the performance of the coating.
  • the ratio of the mass of the binder phase to the reinforcing phase is 3:17; the other processing parameters are the same as in Example 1.
  • Figure 14 shows the morphology of the macroscopic cracks of the coating.
  • the macroscopic cracks appear mainly because the content of the reinforcing phase is more and the content of the binder phase is less. Large tensile stress is generated during the rapid solidification process after melting, and there is insufficient The melt supplements the front of the solidification interface, which eventually leads to macroscopic cracks. At this time, due to the higher content of the reinforcing phase, the hardness and wear resistance of the coating are better, but the coating will produce macroscopic cracks due to uneven solidification and shrinkage, so it does not meet the corresponding standards.
  • the particle size of the reinforcing phase is 2-10 ⁇ m, and the Hall flow rate is 35s/50g; the other processing parameters are the same as in Example 1.
  • the particle size of the reinforced phase is too small, it is easy to absorb moisture and oxidize, which makes the fluidity of the reinforced phase poor, and the phenomenon of powder blocking occurs when the powder is fed into the reinforced phase through the side axis.
  • the particle size of the enhanced phase is 30-40 ⁇ m, and the Hall flow rate is 18s/50g; other processing parameters are the same as in Example 1.
  • the particle size of the reinforcing phase is too large, and the problem of the reinforcing phase falling off occurs during the subsequent processing.
  • the reinforcement phase particles fall off, and the size of the fallen particles is equivalent to the size of the reinforcement phase.
  • the niobium carbide particles are subjected to greater frictional drag during the grinding process.
  • Figure 16 shows the corrosion morphology, and there are more corrosion spots after the corrosion test;
  • Figure 17 is the metallographic photo of the corrosion pits after the corrosion test, there are more corrosion pits at the blade part, and the shape and size of the corrosion pits
  • the diameters of the niobium carbide hard particles are equivalent, and the defects are caused by the shedding of the niobium carbide hard particles. When the corrosion test is performed, corrosion spots are first generated at the defects, and finally serious corrosion pits are caused.
  • the reinforcing phase is tungsten carbide (density 15.8g/cm 3 ), the mass ratio of the binder phase to the reinforcing phase is 19:1; the particle size of the reinforcing phase is 5-20 ⁇ m, the Hall flow rate is 17s/50g; the particle size of the binder phase 53-105 ⁇ m.
  • the density of tungsten carbide particles is much higher than that of the binder phase, they are deposited at the bottom of the molten pool under the action of gravity, resulting in uneven distribution of the reinforcement phase in the coating, that is, the lower part of the coating is more and the upper part is less, as shown in Figure 18. . Because the upper part of the coating has less reinforcing phase, the measured hardness value is lower and the wear resistance is lower.

Abstract

一种刀具涂层的加工方法，包括熔池形成步骤：通过同轴送粉通道将粘结相（1）汇聚于等离子弧热源，粘结相（1）熔化后沉积在刀具基材上形成熔池；增强相（2）添加步骤：通过侧轴送粉通道将增强相（2）送入等离子束移走后的熔池中，并在超声振动的条件下对粘结相（1）和增强相（2）进行熔覆，在刀具表面形成涂层；该加工方法解决了刀具涂层加工过程中存在的硬质相颗粒的送入问题、烧损问题以及在涂层中分布不均匀的问题，提高了刀具涂层的硬度、耐腐蚀性能、耐磨损性能，最终提高刀具的使用寿命。

Description

一种刀具涂层的加工方法 技术领域
本发明涉及一种刀具涂层的加工方法，属于材料加工技术领域。
背景技术
目前，常用的表面复合涂层的制备方法有电镀、表面堆焊、气相沉积、喷涂、激光熔覆以及等离子熔覆等。为了增加涂层的耐磨损、耐腐蚀等性能，常常在制备涂层的过程中加入碳化钨、碳化钛、碳化钒等具有高硬度的碳化物或者氮化物等。基础粉末与较细的硬质颗粒粉末通过球磨工艺均匀混合，然后进行涂层的制备。然而，在基础粉末与硬质相颗粒进行球磨混合的过程中会发生复杂的固相反应，球磨过程中产生的机械力(剪切力、冲击力等)可使金属粉末/硬质颗粒发生塑性变形、断裂、破碎、晶体结构重构等变化，因此球磨工艺改变了原粉末材料的初始形貌及结构特性，这些变化对后续的涂层制备工艺有着不可预估的影响。另外，采用较细的、不规则硬质颗粒粉末进行单独送粉时，容易引起送粉管堵塞的问题；当采用粒径较大的硬质相颗粒进行单独送粉制备涂层时，又存在较大粒径的硬质相在涂层中易剥落的问题。
在激光熔覆与等离子熔覆过程中，硬质相颗粒通常是和基础粉末混合后同时送入热源加热，这样在温度较高热源的作用下，会造成硬质颗粒的部分烧损，造成硬质相颗粒的浪费，且使制备涂层的实际性能不如预期性能。另外，在制备涂层过程中，硬质相颗粒的选择也是关键环节：现有的硬质相选择时未考虑硬质相颗粒与基础粉末材料的密度差问题，常常造成硬质相颗粒在涂层中分布不均匀以及涂层出现裂纹等问题，影响涂层的使用性能。
发明内容
为了克服现有技术的不足，本发明的目的在于提供一种刀具涂层的加工方法，该加工方法解决了刀具涂层加工过程中存在的硬质相颗粒的送入问题、烧损问题以及在涂层中分布不均匀的问题，提高了刀具涂层的硬度、耐腐蚀性能、耐磨损性能，最终提高刀具的使用寿命。
实现本发明的目的可以通过采取如下技术方案达到：一种刀具涂层的加工方法，包括：
熔池形成步骤：通过同轴送粉通道将粘结相汇聚于等离子弧热源，粘结相熔化后沉积在刀具基材上形成熔池；
增强相添加步骤：通过侧轴送粉通道将增强相送入等离子束移走后的熔池中，并在超声振动的条件下对粘结相和增强相进行熔覆，在刀具表面形成涂层。
在一些实施方式中，粘结相为自熔性合金粉末，粘结相密度为6-9g/cm 3，粉末粒径为48-250μm。此处所指粘结相密度为该粉末材料对应的块体材料的密度，而非粉末材料的松装密度或者振实密度。
在一些实施方式中，所述自熔性合金粉末选自：不锈钢、镍基合金、钴基合金中的一种或几种；
在一些实施方式中，所述不锈钢选自：1Cr13、3Cr13、304、316、420、440、RWL34、PMC27、5Cr15MoV、8Cr13MoV、9Cr18MoV中的一种或几种；
在一些实施方式中，所述镍基合金选自Ni60、Ni60A、Ni60W、Ni55、Ni62、Deloro60中的一种或几种；
在一些实施方式中，所述钴基合金选自Co190、CoCrMo、Co800、Tribaloy 800、Stellite20中的一种或几种；
在一些实施方式中，所述自熔性合金粉末选自3Cr13、Ni60A、CoCrMo、8Cr13MoV中的一种或几种。
在一些实施方式中，所述增强相密度为6.1-9.2g/cm 3。该密度与粘结相的密度十分接近。此处所指增强相为该粉末材料对应的块体材料的密度，而非粉末材料的松装密度或者振实密度。
在一些实施方式中，增强相包括碳化锆、碳化铌、氮化铌、氮化锆和硼化铌中的至少一种；增强相为球形颗粒，粒径为5-25μm，霍尔流速小于25s/50g；优选小于18s/50g。
碳化锆、碳化铌、氮化铌、氮化锆和硼化铌，均为高硬度、高熔点，且密度和粘结相相近，密度范围为6.1-9.2g/cm 3，密度相近可以有效防止增强相在涂层中分布不均匀。现有技术中，碳化钨因其高硬度常用来做为增强相，然而，根据实验发现，在本发明的一个技术方案中，以碳化钨做为增强相时，碳化钨沉积在熔池的下层，导致分布不均，且涂层表面耐磨性差。
在一些实施方式中，增强相熔覆步骤中，超声振动的功率为50-300W。
在一些实施方式中，粘结相和增强相的质量之比为20:(1-50)。
在一些优选的实施方式中，粘结相和增强相的质量之比为12:(3-28)。
在一些更优选的实施方式中，粘结相和增强相的质量之比为35:(15-35)。
在一些实施方式中，所述刀具的基材选自碳钢、不锈钢中的一种或几种；
在一些实施方式中，所述刀具基材选自45号碳钢、碳钢Q235、2Cr13不锈钢、3Cr13不锈钢、5Cr15不锈钢、304不锈钢中的一种或几种。
在一个实施方式中，所述刀具基材为3Cr13，粘结相为3Cr13，增强相为碳化铌。
在另一个实施方式中，所述刀具基材为45#碳钢，所述粘结相为Ni60A镍基合金粉末，增强相为碳化锆。
在另一个实施方式中，所述刀具基材为304不锈钢，所述粘结相为CoCrMo钴基合金粉末，增强相为硼化铌。
在另一个实施方式中，所述刀具基材为5Cr15不锈钢，所述粘结相为8Cr13MoV铁基合金粉末，增强相为氮化铌。
在一些实施方式中，同轴送粉通道中轴线和侧轴送粉通道的夹角为15-75度。
在一些实施方式中，同轴送粉通道的出料嘴与刀具基材的距离为5-15mm，粘结相的送入速度为10-25g/min。
在一些实施方式中，侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的水平距离为1-5cm，增强相的送入速度为5-14g/min。
在一些实施方式中，等离子束电弧为联合型等离子弧；
在一些实施方式中，熔覆条件为：离子气流0.6-6L/min，保护气流5-25L/min，送粉气流量0.6-6L/min，熔覆电流3-180A，基值/引弧电流为0-29A，维弧电流为0-20A，熔覆时间50-300ms，间隔时间50-300ms，保护气延时0-5s，电流上升时间及下降时间均为0.1-0.5s，保护气提前0-3s，熔覆速度120-480mm/min。
在一些实施方式中，熔覆条件为：离子气流3-5L/min，保护气流5-10L/min，送粉气流量2-5L/min，熔覆电流20-50A，基值/引弧电流为20-29A，维弧电流为5-10A，熔覆时间80-150ms，间隔时间50-150ms，保护气延时1-3s，电流上升时间及下降时间均为0.1-0.5s，保护气提前0-3s，熔覆速度150-300mm/min。
在一些实施方式中，所述加工方法进一步包含对刀具涂层进行退火、淬火以及回火热处理。
相比现有技术，上述技术方案中的一个技术方案具有如下优点或者有益效果：
1、本发明以同轴送粉结合侧轴送粉的方式，可以降低增强相由于温度过高而造成的烧损 现象；本发明避开了增强相与粘结相通过球磨混合的方法，因为此种方法在球磨过程中会破坏原材料的形貌及表面能，进而影响熔覆工艺及性能。采用侧轴送粉管道将增强相直接送进熔池，而非热源等离子弧，还可以减少由于直接送进热源而产生的烧损作用；
2、本发明在制备刀具涂层的过程中，超声振动的加入对熔覆后熔池金属的流动、结晶形核及晶粒的长大有显著地作用，生长中的晶粒在超声振动下破碎，形成多个形核核心，使形核率增加，最终形成晶粒细小的涂层。另外，超声振动对硬质相颗粒在涂层中的均匀分布具有良好的辅助作用，刀刃部位制备出无裂纹。
附图说明
图1为实施例1加工示意图；
图2为实施例1刀具开刃后的表面形貌；
图3为实施例1刀具开刃后的金相照片；
图4为实施例2刀具开刃后的表面形貌；
图5为实施例2刀具开刃后的金相照片；
图6为实施例3刀具开刃后的表面形貌；
图7为实施例3刀具开刃后的金相照片；
图8为实施例4刀具开刃后的表面形貌；
图9为实施例4刀具开刃后的金相照片；
图10为实施例5刀具开刃后的表面形貌；
图11为实施例5刀具开刃后的金相照片；
图12为实施例6刀具开刃后的表面形貌；
图13为实施例6刀具开刃后的金相照片；
图14为对比例3涂层宏观裂纹形貌；
图15为对比例5刀具开刃后的金相照片；
图16为对比例5腐蚀形貌图片；
图17为对比例5腐蚀坑的金相照片；
图18为对比例6涂层的金相照片；
图中，1、粘结相；2、增强相。
具体实施方式
下面，结合附图以及具体实施方式，对本发明做进一步描述：
一种刀具涂层的加工方法，包括：
熔池形成步骤：通过同轴送粉通道将粘结相汇聚于等离子弧热源，粘结相熔化后沉积在刀具基材上形成熔池；粘结相为自熔性合金粉末，粉末密度为6-9g/cm 3，粉末粒径为48-250μm；
粘结相的粒径限定48-250μm能够克服送粉堵塞的问题；
同轴送粉通道的出料嘴与刀具基材的距离为5-15mm。
增强相添加步骤：通过侧轴送粉通道将增强相送入等离子束移走后的熔池中，并在超声振动功率为50-300W的条件下对粘结相和增强相进行熔覆，在刀具表面形成涂层；
侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的水平距离为1-5cm。
增强相包括碳化锆、碳化铌、氮化铌、氮化锆和硼化铌中的至少一种；增强相为球形颗粒，粒径为5-25μm，霍尔流速小于25s/50g；优选小于18s/50g；
粘结相的粉末密度限定6-9g/cm 3，增强相材料为碳化锆、碳化铌、氮化铌和硼化铌，均为高硬度、高熔点，且密度和粘结相相近，密度范围为6.1-9.2g/cm 3，密度相近可以有效防止增强相在涂层中分布不均匀。传统熔覆技术在进行增强相的选择时，未考虑增强相密度与粘结相密度的关系，容易造成增强相在熔池中由于密度差的问题而不均匀的分布于涂层中，影响涂层性能的均匀性；
粒径为5-25μm内既可以保证增强相顺利送出，还可以防止涂层在后期打磨过程中造成增强相脱落的问题。粒径较小时，细小颗粒在范德华力以及潮湿等作用下容易团聚，造成送粉过程中管道的堵塞；当粒径较大时，虽然侧轴送粉较容易实现，但是涂层在后期开刃打磨过程中容易造成增强相颗粒的脱落；
增强相为球形，且霍尔流速较小，可以保证增强相的顺利送进熔池；当增强相为非球形时，颗粒之间摩擦力较大，流动性能较差，同时造成霍尔流速时间较长，最终导致送粉困难；本发明采用球形粉末，具有良好的流动性能，可以实现侧轴送粉；
粘结相先与微束等离子热源相互作用，在基材上产生熔池，在等离子束移走后熔池凝固之前，增强相送入熔池后，在超声振动的作用可以使得增强相在熔池中的分布更加均匀。
粘结相和增强相的质量之比为20:(1-50)；优选为12:(3-28)；更优选为35:(15-35)。
增强相在粘结相中起到提高硬度、耐磨等作用，均匀分布于涂层中可实现软硬结合的效果，最终增加涂层硬度及耐磨性能；但是增强相含量过少时，强化作用不明显；增强相含量 过多时，粘结相相应地减少，在材料凝固过程中，凝固界面前沿得不到熔液的补充而出现宏观裂纹。
同轴送粉通道中轴线和侧轴送粉通道的夹角为15-75度；
此角度范围可以保证熔覆涂层具有良好的外观形貌，侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的夹角不能太大也不能过小，否则影响熔覆涂层的外观形貌。
等离子束电弧为联合型等离子弧；
即非转移弧和转移弧同时工作，非转移弧的作用是引弧和维弧，使转移弧在小电流下仍能稳定工作，转移弧用于熔化粉末，联合型等离子弧具有电弧稳定、能量密度高、加工工艺窗口宽等优点。
熔覆条件为：离子气流0.6-6L/min，保护气流5-25L/min，送粉气流量0.6-6L/min，熔覆电流3-180A，基值/引弧电流为0-29A，维弧电流为0-20A，熔覆时间50-300ms，间隔时间50-300ms，保护气延时0-5s，电流上升时间及下降时间均为0.1-0.5s，保护气提前0-3s，熔覆速度120-480mm/min；保护气体、离子气体、送粉气体均采用氩气。
优选地，熔覆的条件为：离子气流3-5L/min，保护气流5-10L/min，送粉气流量2-5L/min，熔覆电流20-50A，基值/引弧电流为20-29A，维弧电流为5-10A，熔覆时间80-150ms，间隔时间50-150ms，保护气延时1-3s，电流上升时间及下降时间均为0.1-0.5s，保护气提前0-3s，熔覆速度150-300mm/min。
对制备的刀具涂层进行相应的退火去应力处理，再进行相应的淬火、回火热处理。
实施例1：
如图1所示为加工示意图，粘结相1从同轴送粉通道送粉，增强相2从侧轴送粉通道送粉。
一种刀具涂层的加工方法，包括：
熔池形成步骤：通过同轴送粉通道将粘结相汇聚于等离子弧热源，粘结相熔化后沉积在刀具基材(3Cr13)上形成熔池；粘结相为不锈钢3Cr13(密度7.75g/cm 3)，粉末粒径为53-105μm；同轴送粉通道的出料嘴与刀具基材的距离为8mm，粘结相的送入速度为10g/min；
增强相添加步骤：通过侧轴送粉通道将增强相送入等离子束移走后的熔池中，增强相为密度7.8g/cm 3的碳化铌；增强相为球形颗粒，粒径为5-20μm，霍尔流速17.5s/50g；侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的水平距离为1cm，增强相的送入速度为6g/min；并在超声振动功率为100W的条件下对粘结相和增强相进行熔覆，在刀具表面形成 涂层；
粘结相和增强相的质量之比为19:1；
同轴送粉通道中轴线和侧轴送粉通道的夹角为45度；
等离子束电弧为联合型等离子弧；
熔覆条件为：离子气流3L/min，保护气流6L/min，送粉气流量3L/min，熔覆电流30A，基值/引弧电流为28A，维弧电流为10A，熔覆时间100ms，间隔时间100ms，保护气延时3s，电流上升时间及下降时间均为0.1s，保护气提前2s，熔覆速度240mm/min；保护气体、离子气体、送粉气体均采用氩气。
对制备的刀具涂层进行800℃/30min-缓冷退火处理，950℃/15min-风冷淬火处理，600℃/30min空冷回火处理。
图2为完成涂层加工后，对刀具开刃后的表面形貌，刀刃部位无腐蚀斑点的产生；图3为开刃后金相照片，刃部光滑无缺陷，表明增强相颗粒在粘结相中起到良好的强化作用，同时不影响涂层的腐蚀及打磨开刃。
实施例2：
一种刀具涂层的加工方法
与实施例1不同的是，使用粘结相和增强相的质量之比为3:2；
粘结相粒径为105-180μm；增强相粒径10-25μm，霍尔流速17s/50g；其余加工参数与实施例1相同。
刀具开刃后的表面形貌和金相图片如图4-5所示，表面形貌无腐蚀现象及增强相颗粒脱落的现象。
实施例3：
一种刀具涂层的加工方法
与实施例1不同的是，使用粘结相和增强相的质量之比为3:7；
粘结相粒径为120-200μm；增强相粒径15-25μm，霍尔流速16.5s/50g；其余加工参数与实施例1相同。
刀具开刃后的表面形貌和金相图片如图6-7所示，表面形貌无腐蚀现象及增强相颗粒脱落的现象。
实施例4：
一种刀具涂层的加工方法
与实施例1不同的是，本实施例中基材为5Cr15不锈钢，粘结相为8Cr13MoV铁基合金粉末，粘结相密度为7.82g/cm3，粉末粒径为120-250μm，同轴送粉通道的出料嘴与刀具基材的距离为10mm；增强相为密度7.3g/cm3的球形氮化铌，粒径为8-25μm，霍尔流速20.0s/50g；侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的水平距离为3cm；并在超声振动功率为200W的条件下对粘结相和增强相进行熔覆，采用与实施例1相同的方法及相同的工艺参数在刀具表面形成涂层；
粘结相和增强相的质量之比为1:1；
同轴送粉通道中轴线和侧轴送粉通道的夹角为60度；
对制备的刀具涂层进行1080℃/30min淬火处理，空冷至室温；随后进行500℃/30min回火处理，空冷至室温。
刀具开刃后的表面形貌和金相图片如图8-9所示，表面形貌无腐蚀现象及增强相颗粒脱落的现象。
实施例5
一种刀具涂层的加工方法
与实施例1不同的是，本实施例中基材为304不锈钢，粘结相为CoCrMo钴基合金粉末，粘结相密度为8.53g/cm 3，粉末粒径为120-200μm，同轴送粉通道的出料嘴与刀具基材的距离为13mm；增强相为密度7.2g/cm 3的球形硼化铌，粒径为5-15μm，霍尔流速22.8s/50g；侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的水平距离为5cm；并在超声振动功率为150W的条件下对粘结相和增强相进行熔覆，采用与实施例1相同的方法及相同的工艺参数在刀具表面形成涂层；
粘结相和增强相的质量之比为3:7；
同轴送粉通道中轴线和侧轴送粉通道的夹角为70度；
对制备的刀具涂层进行1100℃/60min固溶处理，随后空冷至室温。
刀具开刃后的表面形貌和金相图片如图10-11所示，表面形貌无腐蚀现象及增强相颗粒脱落的现象。
实施例6
一种刀具涂层的加工方法
与实施例1不同的是，本实施例中基材为45#碳钢，粘结相为Ni60A镍基合金粉末，粘结相密度为7.53g/cm 3，粉末粒径为105-180μm，同轴送粉通道的出料嘴与刀具基材的距离 为10mm；增强相为密度6.4g/cm 3的球形碳化锆，粒径为10-25μm，霍尔流速19s/50g；侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的水平距离为2cm；并在超声振动功率为120W的条件下对粘结相和增强相进行熔覆，采用与实施例1相同的方法及相同的工艺参数在刀具表面形成涂层；
粘结相和增强相的质量之比为3:2；
同轴送粉通道中轴线和侧轴送粉通道的夹角为60度；
对制备的刀具涂层进行300℃/30min-缓冷退火处理。
刀具开刃后的表面形貌和金相图片如图12-13所示，表面形貌无腐蚀现象及增强相颗粒脱落的现象。
对比例1：
一种刀具涂层的加工方法
使用粘结相和增强相的质量之比为19:1；
粘结相粒径为53-105μm；增强相粒径5-20μm，霍尔流速17.5s/50g；对比例1采用球磨混合增强相与粘结相，混合后的粉末采用的是等离子熔覆同轴送粉，而非同轴和侧轴的混合送粉，其余加工参数与实施例1相同。
增强相被送进热源的正下方，是经过热源等离子直接加热的，会出现一定量的烧损，同时由于增强相经过球磨时会改变其结构，综合结果会造成涂层性能有所下降，摩擦性能差。
对比例2：
使用粘结相和增强相的质量之比为97:3；其余加工参数与实施例1相同。
添加增强相的含量较少。所以涂层综合性能低于实施例1，但是性能和对比例1相近，进一步证实球磨混合粉末以及增强相的烧损对涂层的性能有一定的影响。
对比例3：
使用粘结相和增强相的质量之比为3:17；其余加工参数与实施例1相同。
图14所示为涂层宏观裂纹形貌，宏观裂纹的出现主要是因为增强相含量较多，粘结相含量较少，在熔化后快速凝固过程中产生较大的拉应力，同时没有充足的熔液补充凝固界面前沿，最终导致宏观裂纹的产生。此时由于增强相含量较高，因此涂层硬度及耐磨性较好，但是，涂层会由于凝固收缩不均匀而产生宏观裂纹，所以不符合相应的标准。
对比例4：
增强相粒径2-10μm，霍尔流速35s/50g；其余加工参数与实施例1相同。
增强相粒径过小，容易吸潮以及氧化，使得增强相流动性较差，在侧轴送粉送入增强相过程中，出现堵粉现象。
对比例5：
增强相粒径30-40μm，霍尔流速18s/50g；其余加工参数与实施例1相同。
增强相粒径过大，在后续加工过程中出现增强相脱落的问题。
如图15所示，刀具开刃后，增强相颗粒脱落，脱落颗粒的尺寸与增强相尺寸相当，为碳化铌颗粒在打磨过程中，受到较大摩擦的拖拽力的作用，从涂层中脱落；图16为腐蚀形貌，腐蚀试验后出现较多的腐蚀斑点；图17为腐蚀试验后，观察腐蚀坑的金相照片，刀刃部位出现较多的腐蚀坑，腐蚀坑的形状及尺寸和碳化铌硬质颗粒的直径相当，缺陷为碳化铌硬质颗粒脱落造成的，当进行腐蚀试验时，首先在此缺陷处产生腐蚀斑点，并最终造成严重的腐蚀坑。
对比例6：
增强相为碳化钨(密度15.8g/cm 3)，使用粘结相和增强相的质量之比为19:1；增强相粒径5-20μm，霍尔流速17s/50g；粘结相粒径53-105μm。
由于碳化钨颗粒的密度比粘结相大得多，在重力作用下沉积在熔池底部，造成涂层中增强相分布不均匀，即涂层下部较多，上部较少，如图18所示。由于涂层上部增强相较少，因此测得的硬度值偏低，耐磨损性能偏低。
表格1实施例和对比例的检测结果
Figure PCTCN2019109401-appb-000001
Figure PCTCN2019109401-appb-000002
Figure PCTCN2019109401-appb-000003
对于本领域的技术人员来说，可根据以上描述的技术方案以及构思，做出其它各种相应的改变以及变形，而所有的这些改变以及变形都应该属于本发明权利要求的保护范围之内。

Claims (11)

  1. 一种刀具涂层的加工方法，其特征在于包括：
    熔池形成：通过同轴送粉通道将粘结相汇聚于等离子弧热源，粘结相熔化后沉积在刀具基材上形成熔池；
    增强相添加：通过侧轴送粉通道将增强相送入等离子束移走后的熔池中，并在超声振动的条件下对粘结相和增强相进行熔覆，在刀具表面形成涂层。
  2. 如权利要求1所述的刀具涂层的加工方法，其特征在于，所述粘结相为自熔性合金粉末，粘结相密度为6-9g/cm 3，粘结相粉末粒径为48-250μm；
    优选地，所述自熔性合金粉末选自：不锈钢、镍基合金、钴基合金中的一种或几种；
    优选地，所述不锈钢选自：1Cr13、3Cr13、304、316、420、440、RWL34、PMC27、5Cr15MoV、8Cr13MoV、9Cr18MoV中的一种或几种；
    优选地，所述镍基合金选自Ni60、Ni60A、Ni60W、Ni55、Ni62、Deloro60中的一种或几种；
    优选地，所述钴基合金选自Co190、CoCrMo、Co800、Tribaloy 800、Stellite 20中的一种或几种；
    优选地，所述自熔性合金粉末选自3Cr13、Ni60A、CoCrMo、8Cr13MoV中的一种或几种。
  3. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述增强相包括碳化锆、碳化铌、氮化铌、氮化锆和硼化铌中的至少一种；所述增强相为球形颗粒，粒径为5-25μm，霍尔流速小于25s/50g，优选霍尔流速小于18s/50g，增强相密度为6.1-9.2g/cm 3。
  4. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述增强相熔覆步骤中，超声振动的功率为50-300W。
  5. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述粘结相和增强相的质量之比为20:(1-50)；优选为12:(3-28)；更优选为35:(15-35)。
  6. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述同轴送粉通道中轴线和侧轴送粉通道的夹角为15-75度。
  7. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述同轴送粉通道的出料嘴与刀具基材的距离为5-15mm，粘结相的送入速度为10-25g/min。
  8. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述侧轴送粉通道的出料嘴与同轴送粉通道的出料嘴之间的水平距离为1-5cm，增强相的送入速度为5-14g/min。
  9. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述等离子束电弧为联合型等离子弧；
    所述熔覆条件为：离子气流0.6-6L/min，保护气流5-25L/min，送粉气流量0.6-6L/min，熔覆电流3-180A，基值/引弧电流为0-29A，维弧电流为0-20A，熔覆时间50-300ms，间隔时间50-300ms，保护气延时0-5s，电流上升时间及下降时间均为0.1-0.5s，保护气提前0-3s，熔覆速度120-480mm/min。
  10. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，所述刀具的基材选自碳钢、不锈钢中的一种或几种；
    优选地，所述刀具基材选自45号碳钢、碳钢Q235、2Cr13不锈钢、3Cr13不锈钢、5Cr15不锈钢、304不锈钢中的一种或几种。
  11. 如上述任一权利要求所述的刀具涂层的加工方法，其特征在于，还进一步包含对刀具涂层进行退火、淬火以及回火热处理。
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