WO2021239295A1 - Piece d'usure composite - Google Patents
Piece d'usure composite Download PDFInfo
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- WO2021239295A1 WO2021239295A1 PCT/EP2021/057816 EP2021057816W WO2021239295A1 WO 2021239295 A1 WO2021239295 A1 WO 2021239295A1 EP 2021057816 W EP2021057816 W EP 2021057816W WO 2021239295 A1 WO2021239295 A1 WO 2021239295A1
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- WIPO (PCT)
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- zirconia
- alloy
- metal matrix
- metal
- millimeter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/004—Filling molds with powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C13/00—Disintegrating by mills having rotary beater elements ; Hammer mills
- B02C13/26—Details
- B02C13/28—Shape or construction of beater elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C2/00—Crushing or disintegrating by gyratory or cone crushers
- B02C2/005—Lining
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- 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
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- 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
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/12—Metallic powder containing non-metallic particles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/008—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression characterised by the composition
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0475—Impregnated alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/05—Mixtures of metal powder with non-metallic powder
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/05—Mixtures of metal powder with non-metallic powder
- C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1005—Pretreatment of the non-metallic additives
- C22C1/1015—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
- C22C1/1047—Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
- C22C1/1068—Making hard metals based on borides, carbides, nitrides, oxides or silicides
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0242—Making ferrous alloys by powder metallurgy using the impregnating technique
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
- C22C33/0292—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with more than 5% preformed carbides, nitrides or borides
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/04—Making ferrous alloys by melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C2210/00—Codes relating to different types of disintegrating devices
- B02C2210/02—Features for generally used wear parts on beaters, knives, rollers, anvils, linings and the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
- B22F2007/066—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using impregnation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/25—Oxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2303/00—Functional details of metal or compound in the powder or product
- B22F2303/35—Molten metal infiltrating a metal preform
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
Definitions
- the present invention relates to a wearing part produced in a foundry. It relates more particularly to a hierarchical wear part comprising a reinforced part on its most stressed side.
- the reinforced part is obtained by placing a reinforcement made of an aggregate of millimeter grains with millimeter interstices in a mold in preparation for the casting of the wear part.
- the reinforcement also includes centimetric ceramic inserts previously manufactured according to a predefined geometry. The inserts comprise micrometric ceramic particles bound in a first metal matrix and the millimeter interstices of the reinforcement are infiltrated during casting by a second metal matrix. The first metal matrix is independent of the second metal matrix.
- the present invention also provides a method for obtaining said wearing part with its reinforcing structure.
- the wearing parts include ejectors and anvils of vertical-axis crushers, hammers and beaters of horizontal-axis crushers, cones for crushers, tables and vertical mill rollers, armor plates and lifters for ball or bar mills.
- pumps for tar sands or drilling machines we will cite, among others, pumps for tar sands or drilling machines, mining pumps and dredging teeth.
- the present invention aims to overcome the drawbacks of the state of the art and in particular the difficulty of obtaining reinforcement zones comprising a very high concentration of ceramic particles. It also aims to integrate areas with a high concentration of ceramic particles within a three-dimensional structure of aggregated millimeter grains mainly based on alumina-zirconia comprising millimeter interstices which can be infiltrated by the casting ferrous alloy.
- the millimetric grain reinforcement structure simultaneously makes it possible to ensure the positioning of prefabricated inserts of defined geometry and concentrated in ceramic particles such as carbides, nitrides, borides or intermetallic elements in the mold of the wearing part.
- the inserts have a first metal matrix as a binder of the ceramic particles independent of the casting alloy constituting the second metal matrix.
- the present invention discloses a hierarchical wear part comprising a reinforced part comprising zirconia or an alumina-zirconia alloy, said reinforced part also comprising centimetric inserts of predefined geometry, said inserts comprising micrometric particles of carbides , nitrides, metal borides or intermetallic compounds linked by a first metal matrix, said inserts being inserted into a reinforcing structure infiltrated by a second metal matrix, the reinforcing structure comprising a periodic alternation of millimeter zones with high and low concentration of micrometric particles of zirconia or of an alumina-zirconia alloy, the second metal matrix being different from the first metal matrix.
- the reinforced part further comprises millimeter zones of ceramic-metal composite comprising micrometric particles of titanium carbides, of titanium nitrides, or titanium carbonitrides in a binder constituting a third metal matrix, the proportion of these zones relative to the millimeter zones with a high concentration of micrometric particles of zirconia or of an alumina-zirconia alloy is less than 50 % by volume, preferably less than 40% by volume and particularly preferably less than 30% by volume, the third metal matrix being independent of the first and the second metal matrix;
- the insert has a concentration of micrometric particles of carbides, nitrides, metal borides or intermetallic elements between 20 and 95% by volume and at least 30%, preferably at least 40% and particularly preferably at least 50% by volume ;
- the first metal matrix serving as a binder for the micrometric particles of the insert mainly comprises nickel, a nickel alloy, cobalt, a cobalt alloy or a ferrous alloy other than the
- the present invention also discloses a method of manufacturing a wearing part according to the invention comprising the following steps: providing a mold comprising the imprint of a wearing part with a predefined geometry an area to be reinforced; introduction and positioning in said zone to be reinforced of a compact mixture of powders in the form of millimeter granules, zirconia or alumina-zirconia at least partially surrounding one or more prefabricated inserts of defined geometry concentrated in micrometric particles of carbides, nitrides, borides of metals or intermetallic compounds bound by a first metal matrix; casting a ferrous alloy into the mold, said liquid ferrous alloy infiltrating the three-dimensional structure comprising grains of zirconia or an alumina-zirconia alloy at least partially surrounding the prefabricated inserts.
- the inserts of predefined geometry manufactured prior to the casting of said wearing part are produced by powder metallurgy.
- the present invention also discloses the invention in the form of an impactor, an anvil, a cone or a grinding roller.
- Figure 1 schematically shows a wear part with a zone reinforced by a reinforcement comprising cylindrical inserts in prefabricated ceramics surrounded by a structure of aggregated millimeter grains based on zirconia or alumina-zirconia infiltrated by the metal casting.
- FIG. 2 schematically shows the detail of a reinforcement according to the invention consisting of cylindrical inserts in prefabricated ceramics fixed in a structure of millimeter grains based on zirconia or alumina-zirconia.
- Figure 3 schematically shows a horizontal axis crusher beater with the predefined area reinforced by cylindrical inserts of prefabricated ceramics surrounded by a structure of millimeter grains of zirconia or alumina-zirconia with millimeter interstices and porosity infiltrable.
- FIG. 4 schematically represents a vertical mill roller with the predefined zone reinforced by cylindrical inserts of prefabricated ceramics surrounded by a structure of millimeter grains of zirconia or alumina-zirconia with millimeter interstices and infiltrable porosity.
- FIG. 5 schematically represents a crusher anvil with vertical axis with the predefined zone reinforced by cylindrical inserts of prefabricated ceramics surrounded by a structure of millimeter grains of zirconia or alumina-zirconia with millimeter interstices and porosity infiltrable.
- FIG. 6 schematically represents the method of measuring the Féret diameter (with the minimum and maximum Féret diameters). These Feret diameters are used in the process to obtain the average ceramic-to-metal particle size (as explained below).
- prefabricated ceramic-metal composite insert comprising as binder ceramic particles based on carbides, nitrides, borides and intermetallic elements, a first metallic matrix different from the casting metal, the insert being integrated into the structure infiltrable, the assembly having been placed in the mold before casting.
- References 7 and 8 show an alloy of alumina-zirconia particles.
- prefabricated ceramic particles which can represent up to 90% of the total volume of the insert.
- These inserts can be made by any technology but are preferably made by powder metallurgy.
- first metal matrix specific to the ceramic insert This metal matrix which serves as a binder for the particles of carbides, nitrides, borides and intermetallic elements is independent of the second metal matrix resulting from the casting which infiltrates the infiltrable structure based on zirconia and / or alumina-zirconia.
- beater of a crusher with horizontal axis comprising a reinforced structure according to the invention
- the present invention discloses a wear part with increased resistance to wear performed in conventional foundry. It relates more particularly to a wear part comprising a reinforced part according to a predefined geometry with ceramic inserts (cylinders, polygons, cones, etc.) at the scale of a few centimeters previously manufactured and inserted into an infiltrated three-dimensional structure. made up of agglomerated millimeter grains and forming a periodic alternation of millimeter grains and interstices.
- the grains used to manufacture the three-dimensional structure mainly comprise zirconia ZrC> 2 or alumina-zirconia, the composition range of which can vary from 5 to 95% by weight of alumina and from 95 to 5% of zirconia, preferably 10 to 90% and 90 to 10%, and particularly preferably 20 to 80% and 80 to 20%.
- the grains may include stabilizers such as rare earth oxides, in particular yttrium oxide or cerium oxide as a zirconia stabilizer.
- the millimeter grains used to manufacture the three-dimensional reinforcing structure may also comprise, in a proportion of less than 50%, preferably less than 40% and particularly preferably less than 30% by volume, titanium carbides, titanium nitrides or titanium carbonitrides in a third metal matrix which is also independent of the first two (not shown in the figures).
- the third metal matrix serving as a binder for these millimeter grains is preferably based on an iron alloy, a nickel alloy or a molybdenum alloy.
- the volumetric proportion of the metal binder (third metal matrix) is generally between 5 and 60%, preferably between 7 and 45% and particularly preferably between 10 and 35%.
- the size of the titanium carbides, nitrides or carbonitrides are from 0.05 to 75 ⁇ m, preferably from 0.2 to 40 ⁇ m, more preferably from 0.5 to 15 ⁇ m.
- the infiltrable structure therefore consists of a three-dimensional structure of an aggregate of millimeter grains of average size between 0.5 and 10 mm, preferably 0.7 to 6 mm and particularly preferably between 1 and 4 mm .
- Grain interstices depend on the level of compaction and grain size, but are on the order of a millimeter or a fraction of a millimeter. There is thus a "periodic" alternation of grains and interstices and not a "random" alternation.
- the millimeter grains comprise a homogeneous mixture based on zirconia or alumina-zirconia and can be agglomerated / compacted between them by the use of a binder (glue) or else kept in a metal container in order to define geometrically the reinforced area of the wear part.
- binder with setting via the addition of a catalyst allows the realization of the infiltrable structure without cooking, which may be preferred in certain cases where adequate cooking means are not available.
- the nature of the binder is then either of organic type or of mineral type, preferably organic, more preferably of phenolic type.
- binder with a baking setting allows the use of a binder that is more resistant to high temperature.
- the nature of the binder is then of mineral type, preferably of silicate type, more preferably of sodium silicate type.
- the amount of binder (glue) used for producing the infiltrable structure is between 0.5% and 10% by weight, preferably between 1% and 8%, more preferably between 1.5% and 7%.
- the amount of binder is adapted so as to ensure sufficient cohesion of the grains and to limit the production of gas during infiltration by the liquid casting metal and to limit the residual thickness of binder around each grain constituting the three-dimensional structure porous.
- Ceramic inserts intended to be held by the three-dimensional structure of agglomerated grains have for their part any shape, the cylindrical, polygonal or conical shapes being however favorite.
- the diameter of these ceramic inserts, in the case of a cylindrical shape is of the order of 3 to 50 mm, preferably 6 to 30 mm, more particularly 8 to 20 mm and the length of 5 to 300 mm, preferably 10 to 200 mm, in particular 10 to 150 mm.
- the present invention therefore describes a reinforced wear part on its most stressed side or sides obtained by the infiltration of a three-dimensional ceramic structure of agglomerated millimeter grains periodically alternating with millimeter interstices which already incorporates geometric inserts in Prefabricated ceramics of the ceramic-metal composite type generally obtained by powder metallurgy, where the ceramic particles are embedded in a first metal matrix completely independent of the second metal casting matrix, mainly made of steel or liquid iron.
- This technique allows the convenient and robust positioning of inserts of defined geometry and concentrated in carbides, nitrides, metal borides or intermetallic alloys comprising a metal matrix independent of that generated by the casting.
- This first metal matrix existing prior to the casting of said wear part is present from the start in the ceramic-metal composite inserts.
- the pre-existing inserts are integrated into an infiltrable structure comprising agglomerated millimeter grains (padding) of zirconia, alumina-zirconia or ceramic-metallic composite and which will be infiltrated during the casting of the wear part.
- the infiltrable three-dimensional structure can also include a certain proportion of millimeter grains of titanium carbides, titanium nitrides or titanium carbonitrides in a third metal matrix independent of the first two.
- Ceramic-metal composite inserts such as a cylindrical or frustoconical insert.
- This insert can be composed for example of titanium carbides, titanium nitrides or chromium carbides with a minimum concentration of 40% by volume in a first metal matrix based on iron, manganese, nickel or cobalt, for example, that l 'it is “packaged” in an infiltrable structure composed for example of an agglomerate of millimeter grains based on zirconia or alumina-zirconia.
- this infiltrable structure can also include millimeter grains of carbides, nitrides, metal borides or intermetallic elements, preferably titanium carbide, titanium nitride or titanium carbonitride.
- Alumina is known for its low load abrasion resistance properties thanks to its high hardness compared to the hardness of the main natural minerals. Alumina also takes advantage of its low density and its low cost of implementation, whether by melting or by powder sintering. Pure zirconia, for its part, is generally used in the presence of stabilizers. Zirconia in its tetragonal crystallographic form exhibits advantageous mechanical properties for the reinforcement of parts subjected to wear. The addition of between 0.3 to 8% of rare earth oxide such as, for example, yttrium oxide or cerium oxide allows the stabilization of the zirconia in its tetragonal phase.
- Zirconia has greater flexural strength and toughness than alumina.
- the wear resistance of zirconia is particularly good in the case where the surface stresses induced by the abrasive particles are high.
- its lower hardness compared to certain natural minerals, including quartz or free silica limits its use when it is called upon by ores which contain it.
- the production of alumina-zirconia composites makes it possible to improve the properties of the two compounds taken separately, in particular the mechanical strength and the toughness. The evolution of these properties is illustrated in the following figures.
- the choice of the proportion of zirconia in the alumina makes it possible to optimize the hardness / mechanical properties-toughness pair as a function of the wear stresses to which the material is subjected in order to obtain the best performance from the part thus reinforced.
- the present invention therefore makes it possible to achieve not only very high ceramic concentrations, generally greater than 40% by volume but up to 95% by volume in prefabricated geometric inserts or millimeter grains of ceramic composite.
- existing metal but also to choose the specific metal matrix (first and third metal matrix) to these elements and therefore to be independent of the casting metal (second metal matrix) of the wear part which is generally cast iron or chrome steel.
- the present invention allows better performance of wear parts made in reinforced foundry compared to those of the prior art thanks to the localized increase in the wear resistance of the reinforced area by the presence of more particles resistant to wear and / or particles of a different nature by a more suitable metal matrix. It also allows better performance of wear parts produced by adding areas of defined geometry concentrated in carbides, nitrides, metal borides or intermetallic alloys and a metal matrix existing prior to the casting of said wear part.
- the calculation of the average size dso of the particles of carbides, nitrides, metal borides or particles of intermetallic alloys is carried out by means of the following steps.
- a photomicrographic panorama of the polished cross section of a sample is made, so that there are at least 250 complete particles across the field of view.
- This panorama is made by stitching (the process of combining a series of digital images of different parts of a subject into a panoramic view of the whole subject in order to maintain good definition) using a program computer and an optical microscope (for example, a general image field panorama obtained by an Alicona Infinity Focus).
- an appropriate thresholding is carried out in order to segment the image into characteristics of interest (the particles) and in the background, in different levels of gray.
- a manual step of drawing the particles, the scale bar if present and the border of the image on tracing paper is added, as well. than a step of digitizing the tracing paper.
- the Féret diameter (which corresponds to the distance between two parallel tangents, placed perpendicular to the direction of measurement so that the whole of the projection of the particle is between these two tangents) is measured in all the directions for each particle by image analysis software (ImageJ for example). An example is given in figure 6.
- the minimum and maximum Feret diameters of each particle of the image are determined.
- the minimum Feret diameter is the smallest diameter among the set of Feret diameters measured for a particle.
- the maximum Feret diameter is the largest diameter among the set of Feret diameters measured for a particle. Particles touching the edges of the image are ignored in the calculation.
- the average value of the minimum and maximum Feret diameters of each particle is taken as equivalent diameter x.
- the volume distribution of the particle size q3 (x) is then calculated on the basis of spheres of diameter x.
- the average particle size dso is the volume-weighted average size xi , 3 according to the ISO 9276-2: 2014 standard.
- the volume of the wearing part is 10.27 dm 3 . Its mass is 74.16 kg.
- the weight loss of the entire vertical axis impactor part is measured. This is the only way to determine the wear in practice, which depends on a series of factors including the positioning geometry in the impactor. Although mostly worn on the side of the reinforcement, the impactor is also partially worn outside this reinforcement depending on this positioning.
- This infiltrable structure comprises an aggregate of millimeter grains of average size of about 2.5 mm. These grains are agglomerated in a three-dimensional structure using sodium silicate with a predefined shape in a resin mold. In this three-dimensional structure, there is an alternation between grains and millimeter interstices.
- This comparative example therefore presents reinforced parts based on alumina-zirconia, on the most stressed side of the wear part without initially containing centimetric ceramic-metal composite inserts, of cylinder type for example, previously positioned. in a metal matrix different from the ferrous alloy used for the casting. At the end of these steps, a shape of a total volume reinforced with 0.857 dm 3 is manufactured. The weight loss observed during a wear test is 6.795 kg per 100 hours of operation (kg / 100h) on the wear part of the vertical axis impactor. Examples according to the invention Example 1:
- the reinforced part according to the invention comprises a reinforced zone of predefined geometry with cylindrical ceramic inserts previously manufactured to the scale of a few centimeters and previously inserted into an infiltrable structure comprising grains based on electrofused alumina-zirconia with the composition described below. It should be noted that these grains have the same characteristics as those of the comparative example.
- This infiltrable structure comprises an aggregate of millimeter grains of average size of about 2.5 mm. These grains are agglomerated in a three-dimensional structure using a sodium silicate-based glue with a predefined shape in a resin mold. In this three-dimensional structure, there is a periodic alternation between grains and millimeter interstices.
- the ceramic inserts previously manufactured have a cylindrical geometric shape and consist on average of 70 to 80% of micrometric particles of titanium carbides bound by a first metal matrix of the austenitic steel type.
- the diameter of these previously manufactured ceramic inserts is 20 mm.
- the height is 30 mm.
- the 25 ceramic inserts previously manufactured are positioned vertically relative to the filling face in a predefined manner in the resin mold which defines the reinforcement zone by means of notches made in the resin mold and prior to the addition of millimeter grains of alumina-zirconia.
- a three-dimensional structure with a total volume of 0.857 dm 3 is manufactured by casting a AFNOR Z 270 C 27 - M type cast iron.
- This type of cast iron, which constitutes the second metal matrix, is used for all the examples.
- Example 2 Example 1 is repeated but this time, 25 ceramic inserts manufactured beforehand are positioned identically to Example 1, but consist on average of 70 to 80% of micrometric particles of titanium carbides and a first metal matrix in nickel alloy.
- Example 3 Example 3:
- Example 1 is repeated with 25 inserts but this time, the previously manufactured ceramic-metal composite inserts comprise on average from 75 to 85% of micrometric particles of titanium carbonitrides and a first metal matrix based on an alloy of molybdenum.
- Example 4 is repeated with 25 inserts but this time, the previously manufactured ceramic-metal composite inserts comprise on average from 75 to 85% of micrometric particles of titanium carbonitrides and a first metal matrix based on an alloy of molybdenum.
- Example 4 is repeated with 25 inserts but this time, the previously manufactured ceramic-metal composite inserts comprise on average from 75 to 85% of micrometric particles of titanium carbonitrides and a first metal matrix based on an alloy of molybdenum.
- Example 1 is repeated with again 25 inserts of the same size, but the ceramic inserts produced beforehand comprise on average from 80 to 90% of micrometric particles of chromium carbides bound in a first metal matrix based on nickel.
- Example 5 [0059] Example 4 is repeated with again 25 inserts of the same size, where the ceramic inserts previously produced comprise on average from 80 to 90% of micrometric particles of chromium carbides bound in a first metal matrix based on nickel.
- the three-dimensional structure which surrounds the centimetric inserts comprises 25% by volume of millimeter grains comprising on average 80 to 85% of micrometric particles of titanium carbonitrides in a third metal matrix based on a molybdenum alloy.
- the table below shows the weight losses of a wear part of a 74.16 kg vertical axis impactor in new condition, the reinforced volume of which represents approximately 0.857 dm 3 .
- the weight loss is measured after 438 hours of operation and is reduced over 100 hours of operation.
- the wear mechanisms of the wear parts of vertical axis impactors are a complex mixture of material removal by abrasion, micro-chipping by microcrack propagation and impact erosion of the treated particles.
- the wear behavior of a material will depend on a large number of parameters which are themselves interdependent. Among the most significant, we can cite hardness, toughness, modulus of elasticity, mean free path between the different particles, and at different scales (micrometric, millimeter, centimeter) depending on the size and shape of the particles. processed particles, elastic limit, fatigue resistance and ductility.
- Optimizing the geometric distribution of the materials constituting the composite coupled with their nature and therefore their intrinsic properties therefore makes it possible to further increase the overall hardness of the material while maintaining sufficient toughness leading to better performance at the wear.
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- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Food Science & Technology (AREA)
- Composite Materials (AREA)
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Abstract
Description
Claims
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA3185012A CA3185012A1 (fr) | 2020-05-29 | 2021-03-25 | Piece d'usure composite |
CN202180038714.XA CN115867390A (zh) | 2020-05-29 | 2021-03-25 | 复合磨损部件 |
BR112022023593A BR112022023593A2 (pt) | 2020-05-29 | 2021-03-25 | Peça de desgaste hierárquica e método para fabricar uma peça de desgaste |
PE2022002695A PE20231236A1 (es) | 2020-05-29 | 2021-03-25 | Pieza de desgaste compuesta |
AU2021278584A AU2021278584A1 (en) | 2020-05-29 | 2021-03-25 | Composite wear part |
US18/000,245 US20230201920A1 (en) | 2020-05-29 | 2021-03-25 | Composite wear part |
EP21713434.5A EP4157538A1 (fr) | 2020-05-29 | 2021-03-25 | Piece d'usure composite |
ZA2022/12082A ZA202212082B (en) | 2020-05-29 | 2022-11-04 | Composite wear part |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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EP20177458.5 | 2020-05-29 | ||
EP20177458.5A EP3915684A1 (fr) | 2020-05-29 | 2020-05-29 | Pièce d'usure composite |
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Publication Number | Publication Date |
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WO2021239295A1 true WO2021239295A1 (fr) | 2021-12-02 |
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ID=70968769
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/EP2021/057816 WO2021239295A1 (fr) | 2020-05-29 | 2021-03-25 | Piece d'usure composite |
Country Status (10)
Country | Link |
---|---|
US (1) | US20230201920A1 (fr) |
EP (2) | EP3915684A1 (fr) |
CN (1) | CN115867390A (fr) |
AU (1) | AU2021278584A1 (fr) |
BR (1) | BR112022023593A2 (fr) |
CA (1) | CA3185012A1 (fr) |
CL (1) | CL2022003167A1 (fr) |
PE (1) | PE20231236A1 (fr) |
WO (1) | WO2021239295A1 (fr) |
ZA (1) | ZA202212082B (fr) |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0575685A1 (fr) | 1992-06-23 | 1993-12-29 | Sulzer Innotec Ag | Moulage de précision ayant des surfaces d'usure |
WO1998015373A1 (fr) | 1996-10-01 | 1998-04-16 | Hubert Francois | Piece d'usure composite |
US20030213861A1 (en) * | 2002-05-15 | 2003-11-20 | Condon Gary J. | Crusher wear components |
WO2011008439A2 (fr) * | 2009-07-14 | 2011-01-20 | Tdy Industries, Inc. | Rouleau renforcé et procédé de fabrication associé |
US20110287238A1 (en) * | 2010-05-20 | 2011-11-24 | Baker Hughes Incorporated | Methods of forming at least a portion of earth-boring tools, and articles formed by such methods |
WO2014125034A1 (fr) * | 2013-02-18 | 2014-08-21 | Amincem S.A. | Composite à matrice métallique utile comme pièces d'usure dans les industries du ciment et de l'extraction minière |
WO2016008967A1 (fr) | 2014-07-16 | 2016-01-21 | Magotteaux International S.A. | Grains de céramique et leur procédé de fabrication |
CN108348995A (zh) * | 2015-11-12 | 2018-07-31 | 伊诺科有限责任公司 | 用于制造铸造嵌件的粉末组合物、铸造嵌件以及在铸件中获得局部复合区的方法 |
-
2020
- 2020-05-29 EP EP20177458.5A patent/EP3915684A1/fr not_active Withdrawn
-
2021
- 2021-03-25 CN CN202180038714.XA patent/CN115867390A/zh active Pending
- 2021-03-25 BR BR112022023593A patent/BR112022023593A2/pt unknown
- 2021-03-25 EP EP21713434.5A patent/EP4157538A1/fr active Pending
- 2021-03-25 AU AU2021278584A patent/AU2021278584A1/en active Pending
- 2021-03-25 US US18/000,245 patent/US20230201920A1/en active Pending
- 2021-03-25 PE PE2022002695A patent/PE20231236A1/es unknown
- 2021-03-25 CA CA3185012A patent/CA3185012A1/fr active Pending
- 2021-03-25 WO PCT/EP2021/057816 patent/WO2021239295A1/fr unknown
-
2022
- 2022-11-04 ZA ZA2022/12082A patent/ZA202212082B/en unknown
- 2022-11-14 CL CL2022003167A patent/CL2022003167A1/es unknown
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0575685A1 (fr) | 1992-06-23 | 1993-12-29 | Sulzer Innotec Ag | Moulage de précision ayant des surfaces d'usure |
WO1998015373A1 (fr) | 1996-10-01 | 1998-04-16 | Hubert Francois | Piece d'usure composite |
US20030213861A1 (en) * | 2002-05-15 | 2003-11-20 | Condon Gary J. | Crusher wear components |
WO2011008439A2 (fr) * | 2009-07-14 | 2011-01-20 | Tdy Industries, Inc. | Rouleau renforcé et procédé de fabrication associé |
US20110287238A1 (en) * | 2010-05-20 | 2011-11-24 | Baker Hughes Incorporated | Methods of forming at least a portion of earth-boring tools, and articles formed by such methods |
WO2014125034A1 (fr) * | 2013-02-18 | 2014-08-21 | Amincem S.A. | Composite à matrice métallique utile comme pièces d'usure dans les industries du ciment et de l'extraction minière |
WO2016008967A1 (fr) | 2014-07-16 | 2016-01-21 | Magotteaux International S.A. | Grains de céramique et leur procédé de fabrication |
CN108348995A (zh) * | 2015-11-12 | 2018-07-31 | 伊诺科有限责任公司 | 用于制造铸造嵌件的粉末组合物、铸造嵌件以及在铸件中获得局部复合区的方法 |
Also Published As
Publication number | Publication date |
---|---|
PE20231236A1 (es) | 2023-08-21 |
CN115867390A (zh) | 2023-03-28 |
ZA202212082B (en) | 2024-04-24 |
US20230201920A1 (en) | 2023-06-29 |
CL2022003167A1 (es) | 2023-01-13 |
AU2021278584A1 (en) | 2022-12-08 |
EP4157538A1 (fr) | 2023-04-05 |
CA3185012A1 (fr) | 2021-12-02 |
BR112022023593A2 (pt) | 2022-12-20 |
EP3915684A1 (fr) | 2021-12-01 |
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