Fiber-reinforced babbitt metal welding rod and preparation method thereof

Abstract

The invention relates to the technical field of bearing alloys, in particular to a fiber-reinforced babbitt metal welding rod and a preparation method thereof. The welding rod comprises Babbitt metal and reinforced fibers, the welding rod structurally comprises a strip-shaped core layer alloy and an outer layer alloy wrapping the outer side of the core layer alloy, and the reinforced fibers are located in the core layer alloy or the outer layer alloy. According to the method, the reinforcing fibers are bonded to the specific area of the Babbitt metal wafer, the Babbitt metal stack is prepared, the welding rod is prepared through ultrasonic-assisted extrusion, the reinforcing fibers can be distributed in the specific area of the welding rod, and the plasticity or rigidity of the fiber-reinforced Babbitt metal welding rod can be improved by controlling distribution of the reinforcing fibers; and the use performance in different application scenes is improved.

Description

Technical Field

[0001] This invention relates to the field of bearing alloy technology, and more specifically, to a fiber-reinforced Babbitt alloy welding electrode and its preparation method. Background Technology

[0002] Babbitt metal, also known as bearing alloy, is a low-melting-point alloy with hard granular phases distributed in a soft matrix. It exhibits excellent embedding and compliance properties and is widely used in anti-friction materials for sliding bearings. With the continuous emergence of large-scale, high-speed, and heavy-duty industrial machinery, the requirements for high-temperature resistance, high load-bearing capacity, and low coefficient of friction in Babbitt metal are increasing. Introducing reinforcing fibers into Babbitt metal is an ideal solution, effectively improving its mechanical properties and high-temperature resistance.

[0003] However, existing fiber-reinforced Babbitt alloy welding electrodes (wires or rods) have poor performance in welding. For example, arc additive manufacturing typically requires alloy wires with a diameter of 1.2-4mm. During arc additive manufacturing, the wire needs to be bent frequently and multiple times as it passes through the wire feeding mechanism, with bending angles reaching 150 degrees in some applications. Therefore, the plasticity requirements of the alloy wire are high. However, the existing fiber-reinforced Babbitt alloy wires with a diameter of 1.2-4mm have significantly reduced plasticity due to the addition of reinforcing fibers, making it difficult to meet the plasticity requirements of CMT arc additive manufacturing and TIG welding. They are prone to wire breakage during feeding, seriously affecting their performance. On the other hand, manual welding such as flame welding and TIG welding usually requires alloy rods with a diameter of 10-15mm. Because Babbitt alloy is relatively soft, the rods are prone to deformation during production, transportation, and use. Production requires additional electrode straightening processes, and packaging processes are also affected, impacting electrode production efficiency. During use, deformation of about 20° occurs, resulting in poor processability.

[0004] Currently, the preparation of fiber-reinforced Babbitt alloy wires mostly employs the melting and extrusion method. This involves melting a Babbitt alloy ingot containing reinforcing fibers, followed by extrusion and drawing to obtain the Babbitt alloy wire. For example, patent applications 202210291528.3 and 202210292735.0 both utilize this method. However, due to the significant density difference between Babbitt alloy and reinforcing fibers, interfacial non-wetting, and poor metallurgical compatibility, the reinforcing fibers in Babbitt alloy ingots prepared by the traditional melting-casting method suffer severe burn-off and agglomeration. Furthermore, in alloy wires or rods prepared using these methods, the reinforcing fibers are distributed across the entire cross-section of the wire or rod, making it difficult to control the performance of Babbitt alloy welding electrodes according to different application scenarios.

[0005] In view of this, the present invention is hereby proposed. Summary of the Invention

[0006] The primary objective of this invention is to provide a fiber-reinforced Babbitt alloy welding electrode. By controlling the distribution of reinforcing fibers, this invention improves the plasticity or rigidity of the fiber-reinforced Babbitt alloy welding electrode, thereby enhancing its performance in various application scenarios.

[0007] The second objective of this invention is to provide a method for preparing fiber-reinforced Babbitt wire as described above. This method not only solves the problems of fiber burn-off and agglomeration caused by the large density difference between Babbitt alloy and reinforcing fiber, non-wetting interface, and metallurgical incompatibility in the traditional melting and extrusion method, but also enables the regional addition of reinforcing fiber. This allows for the control of the plasticity and rigidity of the fiber-reinforced Babbitt wire according to different application scenarios, thereby improving its performance.

[0008] In order to achieve the above-mentioned objectives of the present invention, the following technical solution is adopted:

[0009] A fiber-reinforced Babbitt alloy welding electrode includes a Babbitt alloy and reinforcing fibers. Its structure includes a strip-shaped core alloy and an outer alloy covering the outside of the core alloy, wherein the reinforcing fibers are located in the core alloy or the outer alloy.

[0010] Preferably, the fiber-reinforced Babbitt metal electrode satisfies either the first condition or the second condition;

[0011] The first condition is that the diameter of the welding electrode is 1.2-4 mm, and the reinforcing fiber is located in the core alloy.

[0012] The second condition is that the diameter of the welding rod is 10-15 mm, and the reinforcing fiber is located in the outer alloy.

[0013] Preferably, in the first condition, the ratio of the diameter of the core alloy to the diameter of the welding electrode is 1:3-2:3.

[0014] Preferably, in the first condition, the elongation of the welding electrode is 8%-18%.

[0015] Preferably, in the second condition, the ratio of the diameter of the core alloy to the diameter of the welding electrode is 3:4-5:6.

[0016] Preferably, in the second condition, the hardness of the outer alloy is 30-35 HBW.

[0017] Preferably, the fiber-reinforced Babbitt alloy welding electrode comprises 100 parts Babbitt alloy and 2-6 parts reinforcing fiber by weight.

[0018] A method for preparing a fiber-reinforced Babbitt alloy welding electrode according to any one of the foregoing embodiments includes the following steps:

[0019] S1. Prepare a Babbitt alloy stack, comprising one of the following steps (a) or (b):

[0020] (a) A Babbitt alloy stack with reinforcing fibers located in the core layer is prepared by the first method or the second method, denoted as the first stack;

[0021] The first method includes: bonding the reinforcing fiber to the central region of at least one side surface of a Babbitt metal disc to obtain a first disc, and stacking a plurality of the first discs together axially to obtain the desired result;

[0022] The second method includes: bonding the reinforcing fiber to the entire surface of at least one side of the Babbitt alloy disc to obtain a second disc; stacking multiple second discs together axially; and fitting a pure Babbitt alloy annular cylinder on the outside of the disc to obtain the final product.

[0023] (b) A Babbitt alloy stack with reinforcing fibers located on the outer layer is prepared by a third or fourth method, denoted as the second stack;

[0024] The third method includes: bonding the reinforcing fiber to the outer annular region of at least one side surface of the Babbitt metal disc to obtain a third disc, and stacking multiple third discs together axially to obtain the desired result;

[0025] The fourth method includes: bonding the reinforcing fiber to the entire ring surface of at least one side of the Babbitt alloy ring sheet to obtain a first ring sheet; stacking multiple first ring sheets together axially and inserting a pure Babbitt alloy round bar inside them;

[0026] S2. The first stack is compressed and pulled; or the second stack is compressed, i.e., axial ultrasound is applied during the compression.

[0027] Preferably, in step S1, the thickness of both the Babbitt alloy disc and the Babbitt alloy ring is 2-10 mm.

[0028] Preferably, in step S1, the thermal failure temperature of the adhesive used to bond the reinforcing fibers is lower than the extrusion temperature in step S2.

[0029] Preferably, in the first method, the ratio of the diameter of the region where the reinforcing fiber is bonded to the diameter of the first disc is 1:3-2:3.

[0030] Preferably, in the second method, the ratio of the diameter of the second disc to the diameter of the first stack is 1:3-2:3.

[0031] Preferably, in the third method, the ratio of the diameter of the region of the third disc core where the reinforcing fiber is not bonded to the diameter of the third disc is 3:4-5:6.

[0032] Preferably, in the fourth method, the ratio of the diameter of the pure Babbitt alloy round bar to the diameter of the second stack is 3:4-5:6.

[0033] Preferably, in step S2, the extrusion temperature is 130-200℃, the preheating temperature before extrusion is 100-130℃, and the extrusion pressure is 350-800MPa.

[0034] Preferably, in step S2, the frequency of the ultrasound is 20-40kHz, the amplitude is 5-30μm, and the power is 1000-2000W.

[0035] Preferably, in step S2, the extrusion ratio is 50:1-250:1.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0037] (1) The fiber-reinforced Babbitt alloy welding electrode provided by the present invention has the reinforcing fiber located in the core layer or the outer layer of the electrode. When the reinforcing fiber is located in the core layer, the electrode has better plasticity. Compared with the fiber-reinforced Babbitt alloy wire used in traditional arc additive manufacturing, the elongation is significantly improved, and it is not easy to break the wire when used in arc additive manufacturing. When the reinforcing fiber is located in the outer layer, the electrode has better rigidity. Compared with the fiber-reinforced Babbitt alloy rod used in traditional manual welding such as flame welding and TIG manual welding, the surface hardness of its outer layer is significantly increased. It is not easy to deform during production, transportation and use, and has high production efficiency and good process performance. The present invention improves the plasticity or rigidity of the fiber-reinforced Babbitt alloy welding electrode by controlling the distribution of the reinforcing fiber, which can improve its performance in different application scenarios.

[0038] (2) The method of this invention involves bonding reinforcing fibers to Babbitt metal sheets and stacking them layer by layer to obtain a stack for extrusion. Axial ultrasonic-assisted extrusion is then applied to break up agglomerated fiber particles during the extrusion process. Through extrusion homogenization and ultrasonic vibration, the fiber material is homogenized within a specific area. Furthermore, axial vibration effectively reduces extrusion pressure and surface roughness, resulting in significant grain refinement. This method allows for the addition of reinforcing fibers at specific locations, controlling the distribution of reinforcing fibers within the Babbitt metal microstructure, and thus regulating the microstructure and properties.

[0039] (3) When the outer layer is pure Babbitt alloy, it can suppress fiber splashing and improve the interlayer bonding quality. Attached Figure Description

[0040] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0041] Figure 1 The fiber distribution diagrams on the first and third discs provided in the embodiments of the present invention are shown; wherein, a is the first disc and b is the third disc;

[0042] Figure 2 This is a schematic diagram of the structure of the first stack and the second stack provided in an embodiment of the present invention; wherein, a is the first stack obtained by the second method, and b is the second stack obtained by the fourth method;

[0043] Figure 3 This is a partial cross-sectional microstructure diagram of the core of the finished filament in Comparative Example 1 of the present invention;

[0044] Figure 4 This is a partial cross-sectional microstructure diagram of the core of the finished yarn in Embodiment 1 of the present invention;

[0045] Figure 5 This is a partial longitudinal section microstructure of the finished alloy rod in Example 4 of the present invention;

[0046] Figure 6 This is a diagram of the fabric structure of the finished yarn along its length in Example 1;

[0047] Figure 7 The image shows a partial longitudinal section of the finished yarn core, with Comparative Example 2 on the left and Example 1 on the right. Detailed Implementation

[0048] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings and specific embodiments. However, those skilled in the art will understand that the embodiments described below are some embodiments of the present invention, but not all embodiments, and are only used to illustrate the present invention, and should not be regarded as limiting the scope of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall be followed. Where the manufacturers of reagents or instruments are not specified, they are all conventional products that can be purchased commercially.

[0049] A first aspect of the present invention provides a fiber-reinforced Babbitt alloy welding electrode, comprising Babbitt alloy and reinforcing fibers, the structure comprising a strip-shaped core alloy and an outer alloy covering the outside of the core alloy, wherein the reinforcing fibers are located in the core alloy or the outer alloy.

[0050] This invention improves the plasticity or rigidity of fiber-reinforced Babbitt alloy welding electrodes by controlling the distribution of reinforcing fibers, thereby enhancing their performance in various application scenarios.

[0051] When the reinforcing fiber is located in the core layer of the welding electrode, the core of the electrode is a Babbitt alloy containing reinforcing fibers, and the outer layer is a pure Babbitt alloy. The pure Babbitt alloy with good plasticity is located on the outside, which can better withstand tensile stress during use, effectively prevent the generation and extension of cracks, and delay fracture. The Babbitt alloy with reinforcing fibers in the core has poor plasticity, but it has little impact on the overall plasticity of the alloy wire. This is because the core mainly bears compressive stress when bending, and the overall plasticity of the welding electrode is better. Under the same fiber content, it can be bent at a larger angle without breaking. When used in arc additive manufacturing, it is less likely to break due to frequent bending during wire feeding, which can significantly improve the performance.

[0052] The aforementioned composite structure also improves welding performance during arc additive manufacturing. The outer pure Babbitt alloy has a low melting point, melting first and contacting the steel substrate during arc welding. According to wetting angle test data, the wetting angle of pure Babbitt alloy on the steel substrate is reduced by approximately 15-20° compared to Babbitt alloy containing reinforcing fibers, significantly improving interfacial wettability. This lead wetting mechanism ensures that the subsequently molten core material can spread uniformly, forming a dense metallurgical bond. The outer molten pool forms a temperature barrier, keeping the core reinforcing fibers in a relatively low-temperature zone. The outer pure Babbitt alloy forms the molten pool first, allowing the subsequently molten core material to spread evenly. The reinforcing fibers can be encapsulated by the molten pool, which effectively suppresses fiber scattering. The layered melting mechanism reduces the time the fibers are exposed to high-temperature environments. The outer molten pool forms physical isolation, reducing heat conduction. The Sn element in the molten pool forms a protective oxide film on the surface of the reinforcing fibers. The layered structure enables thermal gradient control, ensuring that the core temperature remains below the oxidation threshold of the reinforcing fibers. Compared with traditional fiber-reinforced Babbitt wire, the composite structure electrode with the reinforcing fibers located in the core alloy layer and the outer layer being pure Babbitt alloy can significantly reduce spatter and fiber burn-off during arc additive manufacturing, exhibiting better fiber stability.

[0053] When reinforcing fibers are located on the outer layer of the welding electrode, the surface hardness and rigidity of the electrode can be significantly improved. This is because: the high modulus and hardness characteristics of the reinforcing fibers (such as carbon fiber or glass fiber) directly improve the mechanical properties of the outer region; the reinforced interface formed by the reinforcing fibers and the Babbitt alloy matrix effectively suppresses surface deformation; and the directional distribution of the reinforcing fibers optimizes the stress transmission path, further enhancing the deformation resistance of the outer region.

[0054] This invention significantly improves the stiffness and deformation resistance of the bar by reinforcing it with outer fibers, effectively avoiding deformation problems and ensuring the stability of the welding process; it also improves the reliability and consistency of the process; the outer fiber reinforcement layer improves the wear resistance and fatigue resistance of the bar, extending its service life under high temperature and high stress environments; by adding fibers only to the outer area, performance improvement is achieved, and the amount of fiber used can be reduced while achieving the same hardness and rigidity requirements, thus reducing material costs.

[0055] In some specific embodiments of the present invention, the fiber-reinforced Babbitt metal electrode satisfies either the first condition or the second condition.

[0056] The first condition is that the diameter of the welding rod is 1.2-4mm, for example, it can be any one value or any two values ​​from 1.2mm, 1.6mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, and the reinforcing fiber is located in the core alloy.

[0057] The second condition is that the diameter of the welding rod is 10-15mm, for example, it can be any one value or any two values ​​from 10mm, 12mm, 14mm, and 15mm, and the reinforcing fiber is located in the outer alloy.

[0058] Because CMT (Computer-Assisted Metallurgy) arc additive manufacturing and TIG welding processes typically require alloy wires with a diameter of 1.2-4 mm, and the wire feeding process involves frequent bending, sometimes at large angles, necessitating high plasticity, this invention controls the reinforcing fibers within the core alloy layer for electrodes with a diameter of 1.2-4 mm. This allows the outer alloy to have better plasticity, better withstand tensile stress during use, effectively prevent crack initiation and propagation, and delay fracture, thus meeting wire feeding requirements. Simultaneously, during arc additive manufacturing, this structure improves the wettability of the electrode to the substrate, reduces reinforcing fiber spatter and burn-off, and enhances process stability.

[0059] Manual welding processes such as flame welding and TIG welding typically require alloy rods with a diameter of 10-15mm. Babbitt alloy is relatively soft, and the rods are prone to deformation during production, transportation, and use, resulting in low production efficiency and poor processability. Therefore, for welding rods with a diameter of 10-15mm, this invention improves the surface hardness of the welding rod by placing reinforcing fibers on the outer area of ​​the welding rod, thereby enhancing the overall rigidity of the welding rod and avoiding or reducing deformation problems during transportation and use.

[0060] In some specific embodiments of the present invention, in the first condition, the ratio of the diameter of the core alloy to the diameter of the welding electrode is 1:3-2:3. For example, it can be any single value or a range of any two values ​​from 1:3, 5:12, 1:2, 7:12, 2:3. This range balances the reinforcing effect of the core fibers with the plastic protection of the outer layer, ensuring that the thickness of the outer Babbitt alloy is sufficient to suppress crack initiation, while the core fibers provide sufficient strength support. If the ratio is too large, the outer alloy will be too thin, insufficient to cover the microcrack propagation path that may be caused by fiber agglomeration, leading to a decrease in the overall plasticity of the welding electrode and reducing its performance in the arc additive manufacturing process. If the ratio is too small, the reinforcing effect of the core fibers will be weakened.

[0061] In some specific embodiments of the present invention, in the first condition, the elongation of the welding electrode is 8%-18%, for example, it can be any one value or a range of any two values ​​from 8%, 10%, 12%, 15%, to 18%. Compared with traditional Babbitt wire where the reinforcing fibers are distributed across the entire cross-section of the wire, the elongation is significantly improved and it has better plasticity under the same composition.

[0062] In some specific embodiments of the present invention, in the second condition, the ratio of the diameter of the core alloy to the diameter of the welding electrode is 3:4-5:6. For example, it can be any single value or a range of any two values ​​from 3:4, 7:9, 29:36, and 5:6. If the ratio is too small, the thickness of the outer alloy containing reinforcing fibers is too thick, the surface fiber content is too low, and the outer fiber reinforcement layer cannot cover the maximum contact stress area (depth of about 1-2 mm) to resist transportation deformation and welding pressure. The overall rigidity of the welding electrode is not significantly improved, and it is prone to deformation during transportation and use. If the ratio is too large, the fiber reinforcement effect is weakened, and the hardness improvement is not significant.

[0063] In some specific embodiments of the present invention, in the second condition, the hardness of the outer alloy is 30-35 HBW, for example, it can be any one value or a range of any two values ​​among 30 HBW, 31 HBW, 32 HBW, 33 HBW, 34 HBW, and 35 HBW.

[0064] In some specific embodiments of the present invention, the fiber-reinforced Babbitt alloy welding electrode comprises 100 parts Babbitt alloy and 2-6 parts reinforcing fiber by mass. For example, the reinforcing fiber can be any one value or a range of any two values ​​from 2 parts, 3 parts, 4 parts, 5 parts, and 6 parts.

[0065] In some specific embodiments of the present invention, the Babbitt alloy comprises, by mass parts, 8-9 parts antimony, 5-8 parts copper and 84-87 parts tin, for example, SnSb8Cu5, SnSb8Cu8 or SnSb9Cu7; the reinforcing fiber comprises 1-3 parts carbon fiber and 1-3 parts glass fiber, for example, the carbon fiber and glass fiber may be any one value or a range of any two values ​​from 1 part, 1.5 parts, 2 parts, 2.5 parts, 3 parts respectively.

[0066] A second aspect of the present invention provides a method for preparing fiber-reinforced Babbitt alloy welding electrodes as described in any of the foregoing embodiments, comprising the following steps:

[0067] S1. Prepare a Babbitt alloy stack, comprising one of the following steps (a) or (b):

[0068] (a) A Babbitt alloy stack with reinforcing fibers located in the core layer is prepared by the first method or the second method, denoted as the first stack;

[0069] The first method includes: bonding reinforcing fibers to the central region of at least one surface of a Babbitt metal disc to obtain a first disc (e.g., Figure 1 As shown in Figure a), multiple first circular pieces are stacked together along the axial direction to obtain the desired shape.

[0070] The second method includes: bonding reinforcing fibers to the entire surface of at least one side of a Babbitt alloy disc to obtain a second disc; stacking multiple second discs together axially; and fitting a pure Babbitt alloy annular cylinder with a diameter adapted to the outer side of the second disc, thus obtaining (e.g.) Figure 2 (as shown in Figure a);

[0071] (b) A Babbitt alloy stack with reinforcing fibers located on the outer layer is prepared by a third or fourth method, denoted as the second stack;

[0072] The third method includes: bonding reinforcing fibers to the outer annular region of at least one surface of the Babbitt metal disc to obtain a third disc (e.g., Figure 1 As shown in Figure b), multiple third circular pieces are stacked together along the axial direction to obtain the desired result;

[0073] The fourth method includes: bonding reinforcing fibers to the entire ring surface of at least one side of a Babbitt alloy ring to obtain a first ring; stacking multiple first rings together axially; and inserting a pure Babbitt alloy round bar with an inner diameter compatible with the first ring into the stack, thus obtaining (e.g.) Figure 2 (As shown in Figure b);

[0074] S2. Extruding and drawing the first stack; or extruding the second stack to obtain fiber-reinforced Babbitt metal electrodes; applying axial ultrasound during extrusion.

[0075] According to different application scenarios, the method of this invention bonds reinforcing fibers to specific areas of Babbitt alloy discs or rings to achieve regional addition of reinforcing fibers. Then, the fibers are stacked to obtain a stack for extrusion. The uniform distribution of reinforcing fibers in specific areas is achieved through extrusion homogenization and ultrasonic vibration. This method eliminates the step of pre-mixing Babbitt alloy and reinforcing fibers and directly prepares fiber-reinforced Babbitt alloy welding electrodes through ultrasonic-assisted extrusion. It solves the problems of severe fiber burn-off and difficulty in controlling microstructure and properties in the traditional smelting and extrusion method.

[0076] This invention utilizes an assembly structure to further control the size or density of fiber addition areas, achieving directional fiber distribution within the Babbitt alloy matrix. This regionalized control method not only optimizes the interfacial bonding strength between the fiber and the matrix but also enables anisotropic control of material properties through fiber directional distribution. For example, fiber density can be increased in areas requiring high strength, while fiber content can be reduced in areas requiring high toughness, thereby improving the overall performance of the material.

[0077] Compared with existing traditional technologies, the method of this invention has the following advantages: higher controllability of fiber distribution; traditional mixing methods are difficult to achieve accurate fiber positioning, while the method of this invention achieves precise control of fiber distribution; superior interfacial bonding performance; traditional methods are prone to fiber agglomeration or uneven distribution, affecting interfacial bonding strength, while this invention significantly improves the interfacial bonding quality between fibers and the matrix through regional addition; more flexible performance control; traditional technologies are difficult to achieve anisotropic design of material properties, while this invention can flexibly control the strength, toughness, wear resistance, and other properties of the material through the directional distribution of fibers; and stronger process adaptability; this invention is applicable to various fiber types (such as carbon fiber, glass fiber, etc.) and Babbitt alloy matrices, and has broad industrial application prospects.

[0078] Ultrasonic vibration effectively breaks up agglomerated reinforcing fiber particles during extrusion through cavitation and mechanical vibration, achieving uniform fiber distribution in the Babbitt alloy matrix. Simultaneously, the softening effect and stress concentration release generated by ultrasonic vibration significantly reduce extrusion pressure, solving the problem of excessive extrusion pressure caused by high fiber content, improving extrusion efficiency, and reducing equipment load. Furthermore, ultrasonic vibration, through high-frequency impact, reduces the surface roughness (Ra) of the wire by 25%-50%, significantly reducing surface microcracks. This is because ultrasonic vibration promotes plastic flow of the material and reduces surface stress concentration. At the same time, the dynamic recrystallization induced by ultrasonic vibration significantly refines the grains, resulting in a marked reduction in average grain size.

[0079] Compared with existing traditional extrusion technologies, the ultrasonic-assisted extrusion of this invention has the following advantages: (1) better fiber dispersion. Traditional mechanical stirring methods are difficult to avoid fiber agglomeration, while ultrasonic vibration can achieve uniform fiber distribution and improve the performance of composite materials; (2) lower extrusion pressure. Traditional extrusion processes are prone to exceeding the equipment limit when the fiber content is high, while ultrasonic-assisted extrusion can significantly reduce the extrusion pressure and expand the process window; (3) better surface quality. Traditional extrusion of filaments is prone to microcracks and rough defects on the surface, while ultrasonic vibration improves the surface integrity and enhances the service performance of the filaments; (4) more uniform microstructure. Traditional processes have larger and unevenly distributed grain sizes, while the grain refinement effect induced by ultrasonic vibration makes the microstructure more uniform and significantly improves the mechanical properties. These advantages make this invention of significant industrial application value in the preparation of high-performance Babbitt alloy composite filaments.

[0080] The extrusion cylinder and the die are provided with an inlet guide cone angle of 15°-30° (the angle between the inlet and the axial direction). Combined with the cavitation and softening effect generated by axial ultrasonic vibration, the inner and outer metal flows can be advanced synchronously. The extrusion die inlet is provided with a guide cone angle of 15° to 20°. Combined with the axial ultrasonic vibration, it can ensure that the outer fiber reinforced alloy and the core alloy are extruded synchronously, maintaining the stability of the composite structure.

[0081] In some specific embodiments of the present invention, in step S2, the diameter of the welding electrode obtained after extruding and drawing the first stack is 1.2-4 mm. For example, it can be any single value or a range of any two values ​​from 1.2 mm, 1.6 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, and 4 mm. In the first stack, the reinforcing fiber is located in the core, and the outer alloy of the prepared wire has no reinforcing fiber, resulting in better plasticity. Traditional preparation methods use an integral addition of reinforcing fibers, such as... Figure 3 As shown, fibers are distributed across the entire cross-section of the filament, and fiber aggregation is unavoidable. In areas with excessive or clustered fibers on the outer side of the filament, plasticity decreases sharply, making it prone to crack initiation under tensile stress. As the bending angle increases, the cracks propagate inward, eventually leading to fracture. Low plasticity results in frequent filament breakage and numerous filament joints during production, and filament tangling during transportation and packaging. In actual use, filament breakage is also common, severely impacting usability. The method of this invention can produce filaments with better plasticity and a diameter of 1.2-4 mm, overcoming these problems.

[0082] In some specific embodiments of the present invention, in step S2, the diameter of the welding rod obtained after the second stack body is extruded is 10-15mm. In the second stack body, the reinforcing fiber is located on the outside of the stack body. The surface hardness and rigidity of the extruded rod are better, which can solve the deformation problem during transportation and use. It is suitable for application scenarios such as flame welding and TIG manual welding.

[0083] In some specific embodiments of the present invention, in step S1, the thickness of both the Babbitt alloy disc and the Babbitt alloy ring is 2-10 mm, for example, it can be any single value or a range of any two values ​​from 2 mm, 4 mm, 6 mm, 8 mm, to 10 mm. If the thickness of the Babbitt alloy disc or ring is too large, the uniformity of the reinforcing fiber dispersion in the axial direction of the stack will be poor, and the uniformity of the fiber distribution in the axial direction of the extruded product will decrease; if the thickness of the Babbitt alloy disc is too thin, the processing of the Babbitt alloy disc is difficult. Furthermore, the present invention controls the fiber content of the final welding electrode by the thickness of the Babbitt alloy disc and ring and the type of adhesive.

[0084] In some specific embodiments of the present invention, Babbitt metal discs, ring discs, ring cylinders and round bars are obtained by melting and casting.

[0085] In step S1, when bonding reinforcing fibers, adhesive needs to be applied to specific locations on the Babbitt metal sheet beforehand. In some specific embodiments of the present invention, a brush or cloth of a specific shape and size can be used to pick up the adhesive and then apply it to the surface of the Babbitt metal sheet. For example, the shape of the brush or cloth can be circular or annular, and the size can be determined according to the application range of the adhesive (i.e., the distribution range of the reinforcing fibers). This method can achieve rapid application of the adhesive. After applying the adhesive to the Babbitt metal sheet, reinforcing fibers can be added by bonding on one side or both sides, which can achieve rapid positioning and addition of reinforcing fibers. When the size of the adhesive application area is the same, the amount of reinforcing fibers bonded on each Babbitt metal sheet is also basically the same, which can achieve rapid quantitative bonding and improve production efficiency. When it is necessary to adjust the content of reinforcing fibers in the Babbitt metal stack, the number of Babbitt metal discs can be appropriately adjusted while keeping the total amount of Babbitt metal unchanged.

[0086] In some implementations, brushes or cloths of specific shapes and sizes can be attached to the robotic arm to enable assembly line operations and improve production efficiency.

[0087] In some specific embodiments of the present invention, in step S1, the thermal failure temperature of the adhesive used to bond the reinforcing fibers is lower than the extrusion temperature in step S2. Reinforcing fibers are typically low in density and lightweight, making them very easy to move during conventional laying and transfer processes. This can cause fiber aggregation or displacement of the added position, and some reinforcing fibers may even be blown away during the preparation or transfer of the stack, resulting in fiber loss and potentially causing changes in fiber distribution and content, affecting product consistency. The present invention uses an adhesive to bond the reinforcing fibers, achieving temporary fixation of the reinforcing fibers and preventing fiber movement during the preparation and transfer of the stack from affecting fiber distribution and content. As an example, the adhesive used can be PVAL liquid adhesive, which has low adhesion to metals and fibers, is suitable for temporary fixation, and softens at 100°C, essentially losing its adhesive effect, and dehydrates at 160°C, permanently losing its adhesive effect.

[0088] In some specific embodiments of the present invention, in the first method of step (a), the ratio of the diameter of the region where the reinforcing fiber is bonded to the diameter of the first disc is 1:3-2:3. For example, it can be any one value or a range of any two values ​​among 1:3, 5:12, 1:2, 7:12, and 2:3.

[0089] In some specific embodiments of the present invention, in the second method of step (a), the ratio of the diameter of the second disc to the diameter of the first stack is 1:3-2:3. For example, it can be any one value or a range of any two values ​​among 1:3, 5:12, 1:2, 7:12, and 2:3.

[0090] In step (a), controlling the range of the above ratio is to control the distribution range of reinforcing fibers in the welding electrode product, and to avoid the outer alloy being too thin or too thick, which would affect the plasticity and reinforcing effect of the product.

[0091] In some specific embodiments of the present invention, in the third method of step (b), the ratio of the diameter of the region of the core of the third disc where the reinforcing fiber is not bonded to the diameter of the third disc is 3:4-5:6. For example, it can be any one value or a range of any two values ​​among 3:4, 7:9, 29:36, and 5:6.

[0092] In some specific embodiments of the present invention, in the fourth method of step (b), the ratio of the diameter of the pure Babbitt alloy round bar to the diameter of the second stack is 3:4-5:6. For example, it can be any one value or a range of any two values ​​among 3:4, 7:9, 29:36, and 5:6.

[0093] In step (b), controlling the range of the above ratio is to control the distribution range of reinforcing fibers in the welding electrode product, thereby ensuring the surface hardness and rigidity of the product.

[0094] In some specific embodiments of the present invention, the diameter of the Babbitt alloy stack is 50-80 mm, for example, it can be any one value or a range of any two values ​​among 50 mm, 60 mm, 70 mm, and 80 mm; it is consistent with the diameter of the extruder head.

[0095] In some specific embodiments of the present invention, in step S1, the Babbitt alloy stack comprises 100 parts of Babbitt alloy and 2-6 parts of reinforcing fibers. For example, the reinforcing fibers can be any one value or a range of any two points from 2 parts, 3 parts, 4 parts, 5 parts, and 6 parts.

[0096] In some specific embodiments of the present invention, the Babbitt alloy comprises, by mass parts, 8-9 parts antimony, 5-8 parts copper and 84-87 parts tin, for example, SnSb8Cu5, SnSb8Cu8 or SnSb9Cu7; the reinforcing fiber comprises 1-3 parts carbon fiber and 1-3 parts glass fiber, for example, the carbon fiber and glass fiber may be any one value or a range of any two values ​​from 1 part, 1.5 parts, 2 parts, 2.5 parts, 3 parts respectively.

[0097] In some specific embodiments of the present invention, the carbon fiber used is glue-free short-cut carbon fiber with a length of 3-12mm.

[0098] In some specific embodiments of the present invention, the glass fiber used is high silica glass fiber with a length of 3-5 mm.

[0099] In some specific embodiments of the present invention, in step S2, the extrusion temperature is 130-200℃, for example, it can be any one value or a range of any two values ​​among 130℃, 140℃, 150℃, 160℃, 170℃, 180℃, 190℃, and 200℃; the preheating temperature of the extrusion cylinder before extrusion is 100-130℃, for example, it can be any one value or a range of any two values ​​among 100℃, 110℃, 120℃, and 130℃; after the Babbitt alloy stack is placed into the extrusion cylinder, it continues to be preheated for 2-5 minutes, for example, it can be any one value or a range of any two values ​​among 2 minutes, 3 minutes, 4 minutes, and 5 minutes; the extrusion pressure is 350-800MPa, for example, it can be any one value or a range of any two values ​​among 350MPa, 400MPa, 500MPa, 600MPa, 700MPa, and 800MPa.

[0100] In some specific embodiments of the present invention, in step S2, the frequency of the ultrasound is 20-40kHz, for example, it can be any one value or a range of any two values ​​among 20kHz, 25kHz, 30kHz, 35kHz, and 40kHz; the amplitude is 5-30μm, for example, it can be any one value or a range of any two values ​​among 5μm, 10μm, 15μm, 20μm, 25μm, and 30μm; the power is 1000-2000W, for example, it can be any one value or a range of any two values ​​among 1000W, 1200W, 1500W, 1800W, and 2000W.

[0101] In some specific embodiments of the present invention, in step S2, the extrusion ratio is 50:1-250:1. For example, it can be any one value or a range of any two values ​​among 50:1, 100:1, 150:1, 200:1, and 250:1.

[0102] The following detailed description of some embodiments of the present invention is provided in conjunction with specific application examples. Unless otherwise specified, all raw materials used in the embodiments can be obtained commercially available.

[0103] (I) Preparation of high-plasticity alloy wire

[0104] Example 1

[0105] This embodiment provides a highly ductile fiber-reinforced Babbitt wire, which, by mass, consists of 100 parts Babbitt alloy, 2 parts carbon fiber, and 2 parts glass fiber; wherein, the Babbitt alloy is composed of 8 parts antimony, 5 parts copper, and 87 parts tin; the carbon fiber used is glue-free chopped carbon fiber with a length of 12 mm; and the glass fiber used is high-silica glass fiber with a length of 5 mm.

[0106] The preparation method includes the following steps:

[0107] S1. Preparation of Babbitt metal stacks;

[0108] (1) A round Babbitt alloy ingot is obtained by melting and casting. The round plate is 3mm thick and the diameter of the round plate is consistent with the diameter of the extrusion head, φ60mm. Then, it is sandblasted to obtain Babbitt alloy round plates.

[0109] (2) Prepare a circular brush with a diameter of φ30mm, then immerse it in PVAL liquid adhesive to attach the brush to the robotic arm. The robotic arm then sequentially adheres the adhesive to the center of the front and back surfaces of the Babbitt alloy disc for assembly line operation.

[0110] (3) Carbon fiber and glass fiber are uniformly mixed and placed, and carbon fiber and glass fiber are uniformly adhered to the surface of the Babbitt alloy disc with adhesive. The fiber layer thickness is 0.6 mm, resulting in 80 Babbitt alloy discs for extrusion (the first disc, such as...). Figure 1 (as shown in Figure a);

[0111] (4) The extrusion cylinder heating temperature of the extruder is set to 120°C and the preheating time is 1 hour. The extrusion Babbitt alloy discs are placed into the extrusion cylinder of the extruder that has been preheated to 120°C and stacked to obtain the extrusion Babbitt alloy stack.

[0112] S2. Extruding the Babbitt alloy stack at a pressure of 500 MPa and a temperature of 160°C, while simultaneously applying ultrasonic-assisted extrusion at a frequency of 20 kHz, an amplitude of 10 μm, and a power of 1000 W. The ultrasonic vibration is axial and aligned with the extrusion direction. The ultrasonic vibration continues throughout the extrusion process, resulting in a Babbitt alloy extruded wire with a diameter of 4.0 mm. The Babbitt alloy extruded wire is then drawn 15 times to obtain a finished wire with a diameter of 2.0 mm.

[0113] Example 2

[0114] This embodiment provides a highly ductile fiber-reinforced Babbitt wire, which, by mass, consists of 100 parts Babbitt alloy, 3 parts carbon fiber, and 3 parts glass fiber; wherein, the Babbitt alloy is composed of 8 parts by mass of antimony, 8 parts by mass of copper, and 84 parts by mass of tin; the carbon fiber used is glue-free chopped carbon fiber with a length of 12 mm; and the glass fiber used is high-silica glass fiber with a length of 5 mm.

[0115] The preparation method includes the following steps:

[0116] S1. Preparation of Babbitt metal stacks;

[0117] (1) A round Babbitt alloy ingot is obtained by melting and casting. The round plate is 2mm thick and φ30mm in diameter. Then, it is sandblasted to obtain Babbitt alloy round plates.

[0118] (2) Immerse the entire Babbitt metal disc in PVAL liquid adhesive and remove it. Apply adhesive to the entire surface of both sides of the Babbitt metal disc.

[0119] (3) Mix carbon fiber and glass fiber evenly and place them together. Then, evenly adhere carbon fiber and glass fiber to the surface of the Babbitt alloy disc with adhesive. The fiber layer thickness is 0.6 mm, resulting in 120 Babbitt alloy discs for extrusion (second discs).

[0120] (4) A cylindrical Babbitt alloy ingot with an inner diameter of 30 mm and an outer diameter of 60 mm is obtained by smelting and casting. Then, the previously extruded Babbitt alloy discs are stacked into the inside of the cylindrical Babbitt alloy ingot to obtain an extruded Babbitt alloy stack (e.g., ...). Figure 2 (as shown in Figure a);

[0121] (5) Set the extrusion cylinder heating temperature of the extruder to 120°C, and put the extrusion Babbitt alloy discs into the preheated extrusion cylinder of the extruder in sequence for stacking. Preheat for 2-5 minutes to obtain the extrusion Babbitt alloy stack.

[0122] S2. Extruding the Babbitt alloy stack at a pressure of 550 MPa and a temperature of 170°C, while simultaneously applying ultrasonic-assisted extrusion at a frequency of 30 kHz, an amplitude of 15 μm, and a power of 1000 W. The ultrasonic vibration is axial and aligned with the extrusion direction. The ultrasonic vibration continues throughout the extrusion process, resulting in a Babbitt alloy extruded wire with a diameter of 4.0 mm. The Babbitt alloy extruded wire is then drawn 15 times to obtain a finished wire with a diameter of 2.0 mm.

[0123] Example 3

[0124] This embodiment provides a highly ductile fiber-reinforced Babbitt wire, which, by mass, consists of 100 parts Babbitt alloy, 3 parts carbon fiber, and 3 parts glass fiber; wherein, the Babbitt alloy is composed of 8 parts by mass of antimony, 8 parts by mass of copper, and 84 parts by mass of tin; the carbon fiber used is glue-free chopped carbon fiber with a length of 12 mm; and the glass fiber used is high-silica glass fiber with a length of 5 mm.

[0125] The preparation method includes the following steps:

[0126] S1. Preparation of Babbitt metal stacks;

[0127] (1) A round Babbitt alloy ingot is obtained by melting and casting. The round plate is 3.5 mm thick and φ40 mm in diameter. Then, it is sandblasted to obtain Babbitt alloy round plates.

[0128] (2) Immerse the entire Babbitt metal disc in PVAL liquid adhesive and remove it. Apply adhesive to the entire surface of both sides of the Babbitt metal disc.

[0129] (3) Mix carbon fiber and glass fiber evenly and place them together. Then, evenly adhere carbon fiber and glass fiber to the surface of the Babbitt alloy disc with adhesive. The fiber layer thickness is 0.6 mm, resulting in 68 Babbitt alloy discs for extrusion (second discs).

[0130] (4) A cylindrical Babbitt alloy ingot with an inner diameter of 30 mm and an outer diameter of 60 mm is obtained by smelting and casting. Then, the previously extruded Babbitt alloy discs are stacked into the inside of the cylindrical Babbitt alloy ingot to obtain an extruded Babbitt alloy stack (e.g., ...). Figure 2 (as shown);

[0131] (5) Set the extrusion cylinder heating temperature of the extruder to 120°C, and put the extrusion Babbitt alloy discs into the preheated extrusion cylinder of the extruder in sequence for stacking. Preheat for 2-5 minutes to obtain the extrusion Babbitt alloy stack.

[0132] S2. Extruding the Babbitt alloy stack at a pressure of 580 MPa and a temperature of 170°C, while simultaneously applying ultrasonic-assisted extrusion at a frequency of 30 kHz, an amplitude of 15 μm, and a power of 1000 W. The ultrasonic vibration is axial and aligned with the extrusion direction. The ultrasonic vibration continues throughout the extrusion process, resulting in a Babbitt alloy extruded wire with a diameter of 4.0 mm. The Babbitt alloy extruded wire is then drawn 20 times to obtain a finished wire with a diameter of 2.0 mm.

[0133] Comparative Example 1

[0134] The alloy wire has the same composition and diameter as in Example 1, and is prepared using a traditional melting and extrusion method, specifically including the following steps:

[0135] This embodiment provides a highly ductile fiber-reinforced Babbitt wire, which, by mass, consists of 100 parts Babbitt alloy, 2 parts carbon fiber, and 2 parts glass fiber; wherein, the Babbitt alloy is composed of 8 parts antimony, 5 parts copper, and 87 parts tin; the carbon fiber used is glue-free chopped carbon fiber with a length of 12 mm; and the glass fiber used is high-silica glass fiber with a length of 5 mm.

[0136] The preparation method includes the following steps:

[0137] S1. Preparation of Babbitt alloy ingots;

[0138] (1) Melting is carried out by induction melting at a temperature of 600°C until all the material is melted.

[0139] (2) After the temperature drops to 300℃, add 2 parts of glass fiber and 2 parts of carbon fiber to the melt. Then stir the melt with a quartz rod for 3 minutes and pour it into a graphite mold. Cool and demold to obtain a Babbitt alloy ingot with a diameter of 70mm and a height of 280mm.

[0140] (3) The Babbitt alloy ingot is machined to φ60mm and 240mm in height to remove defects such as pores, inclusions and oil stains on the outer skin;

[0141] (4) Set the extrusion cylinder heating temperature of the extrusion press to 120°C and the preheating time to 1 hour. Place the Babbitt alloy ingot for extrusion into the extrusion cylinder of the extrusion press that has been preheated to 120°C.

[0142] S2. Extruding Babbitt alloy ingots at a pressure of 620 MPa and a temperature of 170°C yields Babbitt alloy extruded wire with a diameter of 4.0 mm. The extruded Babbitt alloy wire is then drawn 25 times to obtain a finished wire with a diameter of 2.0 mm.

[0143] Comparative Example 2

[0144] Comparative Example 2 is similar to Example 1, except that: no ultrasound was applied during extrusion, the extrusion pressure was 620 MPa, the extrusion temperature was 170°C, and all other conditions were the same as in Example 1.

[0145] (II) Preparation of high-rigidity alloy rods

[0146] Example 4

[0147] This embodiment provides a high-rigidity fiber-reinforced Babbitt rod, which, by mass, consists of 100 parts Babbitt alloy, 2 parts carbon fiber, and 2 parts glass fiber; wherein, the Babbitt alloy is composed of 8 parts antimony, 5 parts copper, and 87 parts tin; the carbon fiber used is glue-free chopped carbon fiber with a length of 12 mm; and the glass fiber used is high-silica glass fiber with a length of 5 mm.

[0148] The preparation method includes the following steps:

[0149] S1. Preparation of Babbitt metal stacks;

[0150] (1) A round Babbitt alloy ingot is obtained by melting and casting. The round plate is 2.6 mm thick and the diameter of the round plate is the same as the diameter of the extrusion head, φ60 mm. Then, it is sandblasted to obtain Babbitt alloy round plates.

[0151] (2) Prepare a circular brush with an outer diameter of φ60mm and an inner diameter of φ45mm. Then immerse the entire brush in PVAL liquid adhesive and attach it to the robotic arm. The robotic arm will then sequentially adhere the adhesive to the outer ring of the Babbitt alloy disc (single side) for assembly line operation.

[0152] (3) The carbon fiber and glass fiber are uniformly mixed and placed together. The carbon fiber and glass fiber are uniformly adhered to the upper surface of the Babbitt alloy disc with adhesive. The fiber layer thickness is 0.6 mm, resulting in 92 Babbitt alloy discs for extrusion (the third disc, such as...). Figure 1 (as shown in Figure b);

[0153] (4) Set the extrusion cylinder heating temperature of the extruder to 120℃. Place the Babbitt alloy discs for extrusion into the preheated extrusion cylinder of the extruder for stacking, and preheat for 2-5 minutes to obtain the stacked body of Babbitt alloy for extrusion;

[0154] S2. Extruding Babbitt alloy stacks at a pressure of 400 MPa and a temperature of 150°C, while simultaneously applying ultrasonic-assisted extrusion at a frequency of 20 kHz, an amplitude of 10 μm, and a power of 1000 W. The ultrasonic vibration is axial and aligned with the extrusion direction. The ultrasonic vibration continues throughout the extrusion process to obtain a finished Babbitt alloy rod with a diameter of 10.0 mm.

[0155] Example 5

[0156] This embodiment provides a high-rigidity fiber-reinforced Babbitt rod, which, by mass, consists of 100 parts Babbitt alloy, 2 parts carbon fiber, and 2 parts glass fiber; wherein, the Babbitt alloy is composed of 8 parts antimony, 5 parts copper, and 87 parts tin; the carbon fiber used is glue-free chopped carbon fiber with a length of 12 mm; and the glass fiber used is high-silica glass fiber with a length of 5 mm.

[0157] The preparation method includes the following steps:

[0158] S1. Preparation of Babbitt metal stacks;

[0159] (1) A ring-shaped Babbitt alloy ingot is obtained by melting and casting. The ring is 2.6 mm thick, with an inner diameter of φ45 mm and an outer diameter of 60 mm. Then, it is sandblasted to obtain a Babbitt alloy disc.

[0160] (2) Prepare a circular brush with an outer diameter of φ60mm and an inner diameter of φ45mm, then immerse it in PVAL liquid adhesive, attach the brush to the robotic arm, and then use the robotic arm to sequentially adhere the adhesive to the upper surface (single side) of the Babbitt alloy circular ring, and perform assembly line operation.

[0161] (3) Mix carbon fiber and glass fiber evenly and place them together. Adhere carbon fiber and glass fiber evenly to the upper surface of the Babbitt alloy ring sheet with adhesive. The fiber layer thickness is 0.6 mm, and 92 Babbitt alloy ring sheets for extrusion (first ring sheet) are obtained.

[0162] (4) A cylindrical Babbitt alloy ingot with a diameter of 45 mm is obtained by smelting and casting. Then, the extrusion Babbitt alloy ring sheets from step (3) are stacked onto the outside of the cylindrical Babbitt alloy ingot to obtain an extrusion Babbitt alloy stack (e.g., Figure 2 (as shown in Figure b);

[0163] (5) Set the extrusion cylinder heating temperature of the extruder to 120°C, and put the extrusion Babbitt alloy discs into the preheated extrusion cylinder of the extruder in sequence for stacking. Preheat for 2-5 minutes to obtain the extrusion Babbitt alloy stack.

[0164] S2. Extruding Babbitt alloy stacks at a pressure of 400 MPa and a temperature of 150°C, while simultaneously applying ultrasonic-assisted extrusion with an ultrasonic frequency of 30 kHz, an ultrasonic amplitude of 15 μm, and an ultrasonic power of 1000 W. The ultrasonic vibration is axial and aligned with the extrusion direction. The ultrasonic vibration continues throughout the extrusion process to obtain a finished Babbitt alloy rod with a diameter of 10.0 mm.

[0165] Comparative Example 3

[0166] The alloy rods have the same composition and diameter as those in Example 4 and are prepared using the traditional melting and extrusion method.

[0167] This embodiment provides a high-rigidity fiber-reinforced Babbitt rod, which, by mass, consists of 100 parts Babbitt alloy, 2 parts carbon fiber, and 2 parts glass fiber; wherein, the Babbitt alloy is composed of 8 parts antimony, 5 parts copper, and 87 parts tin; the carbon fiber used is glue-free chopped carbon fiber with a length of 12 mm; and the glass fiber used is high-silica glass fiber with a length of 5 mm.

[0168] The preparation method includes the following steps:

[0169] S1. Preparation of Babbitt alloy ingots;

[0170] (1) Melting is carried out by induction melting at a temperature of 600°C until all the material is melted.

[0171] (2) After the temperature drops to 300℃, add 2 parts of glass fiber and 2 parts of carbon fiber to the melt. Then stir the melt with a quartz rod for 3 minutes and pour it into a graphite mold. Cool and demold to obtain a Babbitt alloy ingot with a diameter of 70mm and a height of 280mm.

[0172] (3) The Babbitt alloy ingot is machined to φ60mm and 240mm in height to remove defects such as pores, inclusions and oil stains on the outer skin;

[0173] (4) Set the extrusion cylinder heating temperature of the extrusion press to 120°C and the preheating time to 1 hour. Place the Babbitt alloy ingot for extrusion into the extrusion cylinder of the extrusion press that has been preheated to 120°C.

[0174] S2. Extrusion of Babbitt alloy ingots at a pressure of 460 MPa and a temperature of 150°C yields a finished Babbitt alloy rod with a diameter of 10.0 mm.

[0175] Comparative Example 4

[0176] Comparative Example 4 is similar to Example 4, except that: no ultrasound was applied during extrusion, the extrusion pressure was 450 MPa, the extrusion temperature was 160°C, and all other conditions were the same as in Example 3.

[0177] Experimental Example 1

[0178] The tensile strength, elongation, maximum bending angle, and surface roughness of the finished wires in Examples 1-2 and Comparative Examples 1-2 were tested. The tensile strength and elongation were tested according to standard GB / T228.1-2021, and the surface roughness was tested according to standard GB / T1031-2009. The maximum bending angle detection method is as follows: (1) First, open the two arms of the angle ruler and place the finished welding wire between the two arms to ensure that the welding wire coincides with the center line; (2) Set the test fixture to fix one end of the welding wire and extend the other end of the welding wire by 100mm, with the bending fulcrum located at the starting point of the fixed end; (3) Bend the welding wire at a uniform speed of 5° / s and monitor the surface condition in real time; (4) When the welding wire breaks or a visible crack appears, stop bending immediately and record the angle at this time. This angle is the maximum bending angle. Take the minimum value of 3 tests as the final result. A crack is defined as a continuous surface defect that is visible to the naked eye or a 10x magnifying glass.

[0179] The test results are shown in Table 1.

[0180] Table 1

[0181]

[0182] Depend on Figure 4 As can be seen, in the fiber-reinforced Babbitt wire prepared by the method of the present invention, the reinforcing fibers are mainly distributed in the core of the finished wire.

[0183] Depend on Figure 6 It can be seen that the fiber-reinforced Babbitt wire prepared by the method of the present invention has the reinforcing fibers uniformly distributed along the length direction; Figure 6 The left side is closer to the surface of the filament, and the right side is closer to the core of the filament. Figure 6 The image shows that there are significantly more fibers on the right side than on the left, indicating that the number of fibers in the core of the filament is significantly greater than that on the outside, and also indicating that the fibers are mainly distributed in the core of the finished filament.

[0184] Depend on Figure 7 It is known that ultrasound can refine grains and promote fiber dispersion.

[0185] Experimental Example 2

[0186] The surface hardness and surface roughness of the alloy rods in Examples 4-5 and Comparative Examples 3-4 were tested according to standards GB / T 231.1-2018 and GB / T 1031-2009, respectively. The test results are shown in Table 2.

[0187] Table 2

[0188] Surface hardness HBW Surface roughness Ra Example 4 35 3.6 Example 5 35 3.6 Comparative Example 3 28 6.0 Comparative Example 4 35 6.0

[0189] Depend on Figure 5 As can be seen, in the fiber-reinforced Babbitt alloy rod prepared by the method of the present invention, the reinforcing fibers are mainly distributed on the outer side of the rod.

[0190] Experimental Example 3

[0191] The finished yarns from Example 1 and Comparative Example 1 were used to prepare bushings, and the fiber loss rate and the bonding strength between the bushing and the matrix were tested.

[0192] CMT arc additive manufacturing process for bearing bushes: The equipment is an Austrian Fröhne welding machine (model: TransPlusSynergic 4000CMT) and a Swiss ABB robot system, model IRB2600-20 / 1.65.

[0193] (1) Before welding, the oxide film on the surface of the bearing workpiece must be removed by sandblasting, shot blasting, pickling, mechanical grinding, machining and other methods.

[0194] (2) Welding on the substrate surface adopts CMT welding mode, welding current 130A, welding speed 1200mm / min, lap rate 50%;

[0195] (3) After the bottom layer welding is completed, the weld surface is ground with a grinding device to remove surface oxide film, dust and other impurities that affect the welding quality;

[0196] (4) When performing CMT additive manufacturing on the surface of tin-based Babbitt alloy, the CMT welding mode is selected, the welding current is 70A, the welding speed is 720mm / min, and the overlap rate is 40%.

[0197] (5) The workpiece processed by CMT arc additive manufacturing process is machined to ensure that the shape, size, accuracy, roughness and other properties meet the process requirements.

[0198] The fiber loss rate test is based on the chemical dissolution method: utilizing the fact that the Babbitt matrix (Sn-Sb-Cu) can be dissolved by specific acids, and that carbon fiber / glass fiber is resistant to acids and alkalis, the fiber content is calculated by the mass difference.

[0199] step:

[0200] Sampling: Cut 10-20cm of finished filament and weigh it accurately (recorded as m0);

[0201] Dissolving the matrix: Immerse the sample in a solution of analytical grade HNO and HCl (1:3, constant temperature at 80℃, 0.2-0.5 hours) until the alloy is completely dissolved;

[0202] Filtration and cleaning: Filter residual fibers with a 0.5μm pore size filter membrane and rinse with deionized water until neutral;

[0203] Drying and weighing: Dry at 105℃ for 2 hours, then weigh the fiber (m). f );

[0204] Calculation: Fiber content w f =m f / m0×100%.

[0205] The strength test is based on GB / T 12948-1991 Destructive Test Method for Bimetallic Bond Strength of Sliding Bearings.

[0206] The test results are shown in Table 3.

[0207] Table 3

[0208] Fiber loss rate (%) Bond strength (MPa) Example 1 9 73 Comparative Example 1 30 70

[0209] Although the present invention has been illustrated and described with specific embodiments, it should be understood that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; those skilled in the art should understand that modifications can be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein, without departing from the spirit and scope of the present invention; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention; therefore, this means that all such substitutions and modifications that fall within the scope of the present invention are included in the appended claims.

Claims

1. A fiber-reinforced Babbitt metal welding electrode, characterized in that, It includes a Babbitt alloy and reinforcing fibers, and its structure includes a strip-shaped core alloy and an outer alloy covering the outside of the core alloy, wherein the reinforcing fibers are located in the core alloy or the outer alloy.

2. The fiber-reinforced Babbitt metal welding electrode according to claim 1, characterized in that, The fiber-reinforced Babbitt metal electrode meets either the first condition or the second condition. The first condition is that the diameter of the welding electrode is 1.2-4 mm, and the reinforcing fiber is located in the core alloy. The second condition is that the diameter of the welding rod is 10-15 mm, and the reinforcing fiber is located in the outer alloy.

3. The fiber-reinforced Babbitt metal welding electrode according to claim 2, characterized in that, The first condition satisfies at least one of the following characteristics: (1) The ratio of the diameter of the core alloy to the diameter of the welding rod is 1:3-2:3; (2) The elongation of the welding electrode is 8%-18%.

4. The fiber-reinforced Babbitt metal welding electrode according to claim 2, characterized in that, The second condition satisfies at least one of the following characteristics: (1) The ratio of the diameter of the core alloy to the diameter of the welding electrode is 3:4-5:6; (2) The hardness of the outer alloy is 30-35 HBW.

5. The fiber-reinforced Babbitt metal electrode according to any one of claims 1-4, characterized in that, The fiber-reinforced Babbitt alloy welding electrode comprises 100 parts Babbitt alloy and 2-6 parts reinforcing fiber by weight.

6. The method for preparing the fiber-reinforced Babbitt alloy welding electrode according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Prepare a Babbitt alloy stack, comprising one of the following steps (a) or (b): (a) A Babbitt alloy stack with reinforcing fibers located in the core layer is prepared by a first method or a second method, denoted as the first stack; The first method includes: bonding the reinforcing fiber to the central region of at least one side surface of a Babbitt metal disc to obtain a first disc, and stacking a plurality of the first discs together axially to obtain the desired result; The second method includes: bonding the reinforcing fiber to the entire surface of at least one side of the Babbitt alloy disc to obtain a second disc; stacking multiple second discs together axially; and fitting a pure Babbitt alloy annular cylinder on the outside of the disc to obtain the final product. (b) A Babbitt alloy stack with reinforcing fibers located on the outer layer is prepared by a third or fourth method, denoted as the second stack; The third method includes: bonding the reinforcing fiber to the outer annular region of at least one side surface of the Babbitt metal disc to obtain a third disc, and stacking multiple third discs together axially to obtain the desired result; The fourth method includes: bonding the reinforcing fiber to the entire ring surface of at least one side of the Babbitt alloy ring sheet to obtain a first ring sheet; stacking multiple first ring sheets together axially and inserting a pure Babbitt alloy round bar inside them; S2. The first stack is compressed and pulled; or the second stack is compressed, i.e., axial ultrasound is applied during the compression.

7. The method for preparing fiber-reinforced Babbitt alloy welding electrodes according to claim 6, characterized in that, In step S1, at least one of the following characteristics is satisfied: (1) The thickness of the Babbitt alloy disc and the Babbitt alloy ring is 2-10 mm; (2) The thermal failure temperature of the adhesive used to bond the reinforcing fibers is lower than the extrusion temperature in step S2; (3) In the first method, the ratio of the diameter of the region where the reinforcing fiber is bonded to the diameter of the first disc is 1:3-2:3; (4) In the second method, the ratio of the diameter of the second disc to the diameter of the first stack is 1:3-2:3; (5) In the third method, the ratio of the diameter of the region of the core of the third disc where the reinforcing fiber is not bonded to the diameter of the third disc is 3:4-5:6; (6) In the fourth method, the ratio of the diameter of the pure Babbitt alloy round bar to the diameter of the second stack is 3:4-5:

6.

8. The method for preparing fiber-reinforced Babbitt alloy welding electrodes according to claim 6, characterized in that, In step S2, the extrusion temperature is 130-200℃, the preheating temperature before extrusion is 100-130℃, and the extrusion pressure is 350-800MPa.

9. The method for preparing fiber-reinforced Babbitt alloy welding electrodes according to claim 6, characterized in that, In step S2, the frequency of the ultrasound is 20-40kHz, the amplitude is 5-30μm, and the power is 1000-2000W.

10. The method for preparing fiber-reinforced Babbitt alloy welding electrodes according to claim 6, characterized in that, In step S2, the extrusion ratio is 50:1-250:1.

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