A method for synthesizing a high-performance oxidation-resistant wear-resistant alloy

Abstract

This invention provides a method for synthesizing a high-performance oxidation-resistant and wear-resistant alloy. The method includes the following steps: S1: Multi-component compounding and pretreatment purification, using Fe, Ni, and Co as the main matrix elements, combined with Cr and Al as core oxidation-resistant elements, adding Nb, Ti, and B as wear-resistant strengthening elements, and supplemented with trace amounts of rare earth elements Ce, Y, and Si as interface modification and oxide film regulation elements. The synthesis method of the high-performance oxidation-resistant and wear-resistant alloy provided by this invention offers strong controllability of process parameters, effectively avoiding problems such as component segregation and microstructure defects. The batch performance fluctuation of the alloy is only 3%, balancing feasibility and economy, suitable for laboratory research and development as well as industrial mass production. Furthermore, the alloy achieves a balance between strength and toughness through multiple strengthening mechanisms, meeting the impact toughness standards for high-end materials. It can be used in metallurgical rolls and mechanical wear-resistant parts, and is also suitable for high-end fields such as aerospace, nuclear power, and high-temperature valves, significantly broadening its application scenarios.

Description

Technical Field

[0001] This invention relates to the field of wear-resistant alloy synthesis technology, and in particular to a method for synthesizing a high-performance oxidation-resistant wear-resistant alloy. Background Technology

[0002] Wear-resistant alloys are a class of special alloys that significantly improve the wear resistance of materials by rationally adjusting the composition and microstructure of metallic elements. They are usually based on iron, nickel, cobalt, etc., and reinforced with alloying elements such as carbon, chromium, tungsten, molybdenum, and manganese. Through casting, forging, or heat treatment, they form a wear-resistant phase with high hardness and high toughness. They mainly rely on the hard phase to resist abrasive wear, adhesive wear, and other damage, while ensuring that the matrix has a certain strength and toughness and is not easy to crack. They are widely used in harsh and easily worn parts in machinery, mining, metallurgy, molds, etc., and greatly extend the service life while maintaining the structural integrity.

[0003] The synthesis of high-performance anti-oxidation and wear-resistant alloys involves precisely proportioning base metals such as iron, nickel, and cobalt with alloying elements such as chromium, tungsten, molybdenum, and aluminum. These alloys are then smelted, cast, or formed using powder metallurgy, followed by heat treatment processes such as solution treatment and aging to regulate the alloy microstructure and the distribution of reinforcing phases. This process is completed at high temperatures or in a specific atmosphere, allowing the alloy to simultaneously form a dense anti-oxidation film and a hard wear-resistant phase. This ensures high-temperature stability, oxidation resistance, and wear resistance, meeting the long-life service requirements under harsh working conditions.

[0004] In the traditional process of synthesizing anti-oxidation and wear-resistant alloys, uneven distribution of internal strengthening phases, coarse grains, and weak grain boundary bonding are common problems. At high temperatures, grain slippage and phase shedding are easy to occur, leading to wear resistance degradation. Loose and porous oxide films are easily formed with poor bonding force, which are prone to peeling off under cyclic high temperatures. There is no long-term anti-oxidation effect, and wear resistance and anti-oxidation are difficult to coordinate. Hardening makes the alloy brittle, while improving anti-oxidation reduces wear resistance. The alloys have poor adaptability to working conditions and cannot meet the stringent requirements of high-end equipment.

[0005] Therefore, it is necessary to provide a method for synthesizing high-performance oxidation-resistant and wear-resistant alloys to solve the above-mentioned technical problems. Summary of the Invention

[0006] This invention provides a method for synthesizing a high-performance anti-oxidation and wear-resistant alloy, which solves the problems of uneven microstructure and easy peeling of oxide film in traditional anti-oxidation and wear-resistant alloys, making it difficult to achieve synergy between wear resistance and oxidation resistance and meet the stringent requirements of high-end equipment.

[0007] To solve the above-mentioned technical problems, the present invention provides a method for synthesizing high-performance oxidation-resistant and wear-resistant alloys, comprising the following steps: S1: Multi-component compounding and pretreatment purification. Fe, Ni, and Co are the main matrix elements, combined with Cr and Al as the core antioxidant elements, and Nb, Ti, and B are added as wear-resistant strengthening elements. Trace amounts of rare earth Ce, Y, and Si are added as interface modification and oxide film control elements. The purity of each element is strictly controlled to 99.95% to avoid the introduction of impurities that induce structural defects. After being accurately weighed according to the preset composition ratio, the metal raw materials are sequentially pickled to remove oxide scale, ultrasonically cleaned with anhydrous ethanol, and vacuum dried to remove surface oil, oxide impurities, and moisture. At the same time, rare earth elements are vacuum-sealed for pretreatment to prevent oxidation and burn-off during the melting process, ensuring the accuracy and uniformity of the subsequent alloy composition and laying the foundation for subsequent uniform alloying. S2: Vacuum gradient staged melting to achieve homogenization of the initial melt. Pre-treated raw materials are loaded into the vacuum induction melting furnace in the order of adding high-melting-point refractory elements first, followed by low-melting-point easily fusible elements. After the furnace is closed, a vacuum of 10... - Below Pa, high-purity argon is introduced as a protective gas to prevent the oxidation of alloying elements during the melting process. A gradient heating staged melting mode is adopted to fully melt and diffuse high-melting-point Nb, Ti, and Cr elements. After cooling, low-melting-point Ni, Al, and rare earth elements are added and held at the temperature for 20-30 minutes. S3: Directional temperature-controlled solidification refines the matrix grain structure. The homogenized alloy initial melt is rapidly transferred to a directional solidification mold. A temperature-controlled solidification process coupled with slow cooling and directional heat dissipation is used to control the solidification temperature gradient and solidification rate, avoiding internal stress concentration and loose structure caused by rapid solidification. Directional heat dissipation guides the grains to grow in a single direction. Combined with the high entropy effect of the alloy system, excessive growth of columnar crystals is suppressed, and the matrix grains are refined to the submicron level. At the same time, it promotes the in-situ uniform precipitation of strengthening phases, reduces grain boundary defects and shrinkage porosity, and improves the matrix density and grain boundary bonding strength, providing a high-quality microstructure for subsequent strengthening and modification. S4: In-situ composite strengthening phase regulation precipitation. The solidified alloy billet is transferred to a vacuum heat treatment furnace for two-stage isothermal heat treatment to regulate the morphology and distribution of the strengthening phase. The first stage is low-temperature pretreatment: the temperature is raised to 600-650℃ and held for 2-3 hours to eliminate the internal stress of the alloy solidification and stabilize the matrix structure. The second stage is high-temperature aging treatment: the temperature is raised to 900-950℃ and held for 4-5 hours to induce the full reaction of C, B, Ti, and Nb elements inside the alloy, and to generate nano-scale TiC, NbB2, and Cr7C3 composite hard phases in situ. The aging temperature and time are strictly controlled to avoid the aggregation and coarsening of the strengthening phase, so that the hard phase is uniformly dispersed in the matrix grains and grain boundaries. This not only greatly improves the hardness and wear resistance of the alloy, but also avoids the increase in matrix brittleness caused by excessive precipitation of hard phase, thus achieving synergistic optimization of wear resistance and toughness. S5: Active element interface dispersion modification. A low-temperature plasma doping process is used to modify the surface and grain boundary interface of the heat-treated alloy billet. Trace amounts of rare earth elements Ce and Y are uniformly dispersed into the alloy surface and near-surface grain boundaries. The doping temperature is controlled at 450-500℃, and the doping time is 1.5-2 hours. A vacuum atmosphere ensures no oxidation loss of active elements. The rare earth elements are dispersed at the grain boundaries, purifying them, strengthening grain boundary bonding, and inhibiting grain boundary slip and crack initiation under high-temperature conditions. Simultaneously, during subsequent oxidation, the rare earth elements can segregate at the oxide film-substrate interface, improving oxide film adhesion, reducing internal stress, and solving the problem of easy peeling of traditional alloy oxide films, thus solidifying the foundation for an anti-oxidation interface. S6: High-temperature pre-oxidation and shaping to build a dense protective oxide film. The interface-modified alloy is placed in a controlled atmosphere furnace for constant-temperature pre-oxidation and shaping treatment. This simulates high-temperature service conditions and builds a stable protective oxide film in advance. The oxidation temperature is controlled at 850-900℃, and the oxidation atmosphere is air + trace water vapor. The temperature is maintained for 3-4 hours. Under the induction of active sites, the Cr and Al elements on the alloy surface undergo rapid selective oxidation to generate a composite oxide film with continuous and dense Al2O3 and Cr2O3 as the core, doped with rare earth oxides and SiO2. The film thickness is controlled at 10-15 μm, without pores or cracks, and tightly bonded to the substrate. The pre-oxidation process can eliminate residual stress on the alloy surface, allowing the oxide film to adapt to high-temperature conditions in advance, avoiding disordered growth, cracking and peeling of the oxide film during actual service, and achieving long-term anti-oxidation. S7: Low-temperature stress-relief finishing stabilizes the overall performance of the alloy. The pre-oxidized alloy undergoes low-temperature stress-relief annealing finishing, with the temperature raised to 300-350℃ and held for 1-1.5 hours. It is then slowly cooled to room temperature in the furnace to completely eliminate residual internal stress generated during the melting, solidification, heat treatment, and pre-oxidation processes. This prevents deformation and cracking of the alloy during service due to internal stress. After finishing, the alloy surface is polished to remove the loose oxide layer and retain a dense protective oxide film. The final product is an alloy with uniform structure, strength and toughness, and excellent oxidation and wear resistance, ensuring batch stability and service reliability. Low-temperature stress-relief finishing requires strict control over every detail and must be carried out entirely within a vacuum heat treatment furnace, where the vacuum level must be maintained stably at 10°C. - Heating in an oxygen-containing air atmosphere is strictly prohibited above Pa to prevent the dense protective oxide film on the alloy surface from being oxidized and eroded. The heating rate should be strictly controlled at 3-5℃ / min, and a step-by-step slow heating method should be adopted. Rapid heating is prohibited to prevent secondary thermal stress. During the holding stage, the temperature difference in the furnace must not exceed 5℃ to ensure uniform stress relief in the alloy billet. During the cooling stage, the furnace must be cooled slowly. Air cooling and water cooling are strictly prohibited.

[0008] Preferably, the gradient heating is controlled at 1500-1600℃ for 30-40 min and 1400-1450℃, respectively; the solidification temperature gradient is controlled at 50-80℃ / cm; the solidification rate is controlled at 5-10 mm / min; and the water vapor content is 5%-8%.

[0009] A method for synthesizing high-performance oxidation-resistant and wear-resistant alloys, wherein the vacuum induction melting furnace required in step S2 includes: a mounting frame; A vacuum grading melting assembly is mounted on top of a mounting base via a bracket. A top cover is installed on the top of the vacuum grading melting assembly, and a discharge assembly is installed on the bottom of the vacuum grading melting assembly. The shape of the vacuum staged melting assembly can be referenced. Figure 2 The top of the cover and the outer surface of the vacuum grading melting assembly are equipped with inlets and outlets for vacuum equipment, which can maintain the vacuum condition inside the vacuum grading melting assembly.

[0010] Preferably, a control box with a door is installed on the top of the mounting base, and an operation panel is installed on one side of the control box. The mounting base includes a base plate, a mounting structure, and an adjustment structure. The mounting structure is used to install the adjustment structure on the bottom of the base plate.

[0011] Preferably, monitoring components are installed on the top of the top cover and the outer surface of the vacuum grading melting assembly, a heating device is installed on the outer surface of the vacuum grading melting assembly, and a temperature control device is installed on the top of the mounting base. The temperature control device can independently control the operation and temperature of the heating equipment on the outer surface of the vacuum grading melting assembly, while the monitoring component can monitor the temperature and humidity changes inside the vacuum grading melting assembly.

[0012] Preferably, a second feed pipe is installed on the top of the top cover, a first feed pipe is installed on the outer surface of the vacuum grading melting assembly, and the discharge assembly includes a valve and a discharge pipe, wherein the valve is used to install the discharge pipe at the bottom of the vacuum grading melting assembly.

[0013] Preferably, the vacuum grading melting assembly includes a first melting chamber, a connecting pipe, a second melting chamber, and a sealing structure. The connecting pipe is used to install the first melting chamber on top of the second melting chamber, and the sealing structure is installed on the outer surface of the connecting pipe. The sealing structure is used to ensure the sealing of the connection between the shaft and the connecting pipe, but does not affect the rotation of the shaft.

[0014] Preferably, a driving device is installed on the outer surface of the vacuum grading melting assembly, and a separating component is installed at the output end of the driving device.

[0015] Preferably, the separating assembly includes a separating disk, a first sealing ring, a rotating shaft, and a second sealing ring. The rotating shaft is used to mount the separating disk at the output end of the driving device, and the first and second sealing rings are mounted on the inner surface of the connecting pipe. The first and second sealing rings and the top and bottom of the separator are misaligned, which does not affect the rotation of the separator but ensures the sealing performance. All separator components are made of high-temperature resistant materials.

[0016] Preferably, the monitoring component includes a fixed base and a monitoring device, wherein the fixed base is used to mount the monitoring device on the top of the top cover or on the outer surface of the vacuum grading melting component.

[0017] Compared with related technologies, the synthesis method of high-performance oxidation-resistant and wear-resistant alloy provided by the present invention has the following beneficial effects: This invention provides a method for synthesizing a high-performance oxidation-resistant and wear-resistant alloy. This method achieves an alloy hardness of 65-72 HRC, a hardness retention rate of 85% at 800℃, a friction coefficient below 0.25, a wear rate reduced by more than 60% compared to traditional alloys, and a high-temperature oxidation weight gain rate reduced by more than 70%. The composite oxide film exhibits no cracking or peeling after hundreds of cycles from room temperature to 900℃. It is suitable for extreme working conditions involving high temperature, high load, and oxidation wear, achieving a synergistic improvement in wear resistance and oxidation resistance. The alloy matrix grains are refined to submicron level, with uniformly dispersed reinforcing phases, clean and robust grain boundaries, a density of 99.5%, and no segregation. The process effectively inhibits oxygen diffusion and wear crack propagation by eliminating defects such as porosity, extending service life by more than 2 times compared to traditional alloys and significantly reducing equipment maintenance costs. This process uses conventional equipment without complex intelligent systems, and the process parameters are highly controllable, effectively avoiding problems such as compositional segregation and microstructure defects. The alloy batch performance fluctuates by 3%, balancing feasibility and economy, and is suitable for laboratory research and development as well as industrial mass production. In addition, the alloy achieves a balance between strength and toughness through multiple strengthening mechanisms, and its impact toughness meets the standards for high-end materials. It can be used in metallurgical rolls, mechanical wear-resistant parts, and is also suitable for high-end fields such as aerospace, nuclear power, and high-temperature valves, greatly expanding its application scenarios. Attached Figure Description

[0018] Figure 1 A schematic diagram of the first embodiment of the synthesis method of the high-performance anti-oxidation and wear-resistant alloy provided by the present invention; Figure 2 A schematic diagram of the structure of a second embodiment of the synthesis method of the high-performance anti-oxidation and wear-resistant alloy provided by the present invention; Figure 3 A schematic diagram of the installation structure is provided for this invention; Figure 4 A schematic diagram of the connecting pipe is provided for this invention; Figure 5 Provided for the present invention Figure 4An enlarged view of point A shown; Figure 6 Provided for the present invention Figure 4 A magnified view of point B shown.

[0019] The diagram is labeled as follows: 1. Mounting base; 101. Base plate; 102. Mounting structure; 103. Adjustment structure; 2. Control box; 3. Box door; 4. Operation panel; 5. Bracket; 6. First feed pipe; 7. Drive device; 8. Second feed pipe; 9. Monitoring component; 901. Fixed base; 902. Monitoring component; 10. Top cover; 11. Heating device; 12. Vacuum grading melting component; 121. First melting chamber; 122. Connecting pipe; 123. Second melting chamber; 124. Sealing structure; 13. Discharge component; 131. Valve; 132. Discharge pipe; 14. Temperature control device; 15. Separation component; 151. Separation plate; 152. First sealing ring; 153. Rotating shaft; 154. Second sealing ring. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] First Embodiment Please refer to the following: Figure 1 ,in, Figure 1 This is a schematic diagram of a first embodiment of the synthesis method for the high-performance oxidation-resistant and wear-resistant alloy provided by the present invention. The synthesis method for the high-performance oxidation-resistant and wear-resistant alloy includes the following steps: S1: Multi-component compounding and pretreatment purification. Fe, Ni, and Co are the main matrix elements, combined with Cr and Al as the core antioxidant elements, and Nb, Ti, and B are added as wear-resistant strengthening elements. Trace amounts of rare earth Ce, Y, and Si are added as interface modification and oxide film control elements. The purity of each element is strictly controlled to 99.95% to avoid the introduction of impurities that induce structural defects. After being accurately weighed according to the preset composition ratio, the metal raw materials are sequentially pickled to remove oxide scale, ultrasonically cleaned with anhydrous ethanol, and vacuum dried to remove surface oil, oxide impurities, and moisture. At the same time, rare earth elements are vacuum-sealed for pretreatment to prevent oxidation and burn-off during the melting process, ensuring the accuracy and uniformity of the subsequent alloy composition and laying the foundation for subsequent uniform alloying. S2: Vacuum gradient staged melting to achieve homogenization of the initial melt. Pre-treated raw materials are loaded into the vacuum induction melting furnace in the order of adding high-melting-point refractory elements first, followed by low-melting-point easily fusible elements. After the furnace is closed, a vacuum of 10... - Below Pa, high-purity argon is introduced as a protective gas to prevent the oxidation of alloying elements during the melting process. A gradient heating staged melting mode is adopted to fully melt and diffuse high-melting-point Nb, Ti, and Cr elements. After cooling, low-melting-point Ni, Al, and rare earth elements are added and held at the temperature for 20-30 minutes. S3: Directional temperature-controlled solidification refines the matrix grain structure. The homogenized alloy initial melt is rapidly transferred to a directional solidification mold. A temperature-controlled solidification process coupled with slow cooling and directional heat dissipation is used to control the solidification temperature gradient and solidification rate, avoiding internal stress concentration and loose structure caused by rapid solidification. Directional heat dissipation guides the grains to grow in a single direction. Combined with the high entropy effect of the alloy system, excessive growth of columnar crystals is suppressed, and the matrix grains are refined to the submicron level. At the same time, it promotes the in-situ uniform precipitation of strengthening phases, reduces grain boundary defects and shrinkage porosity, and improves the matrix density and grain boundary bonding strength, providing a high-quality microstructure for subsequent strengthening and modification. S4: In-situ composite strengthening phase regulation precipitation. The solidified alloy billet is transferred to a vacuum heat treatment furnace for two-stage isothermal heat treatment to regulate the morphology and distribution of the strengthening phase. The first stage is low-temperature pretreatment: the temperature is raised to 600-650℃ and held for 2-3 hours to eliminate the internal stress of the alloy solidification and stabilize the matrix structure. The second stage is high-temperature aging treatment: the temperature is raised to 900-950℃ and held for 4-5 hours to induce the full reaction of C, B, Ti, and Nb elements inside the alloy, and to generate nano-scale TiC, NbB2, and Cr7C3 composite hard phases in situ. The aging temperature and time are strictly controlled to avoid the aggregation and coarsening of the strengthening phase, so that the hard phase is uniformly dispersed in the matrix grains and grain boundaries. This not only greatly improves the hardness and wear resistance of the alloy, but also avoids the increase in matrix brittleness caused by excessive precipitation of hard phase, thus achieving synergistic optimization of wear resistance and toughness. S5: Active element interface dispersion modification. A low-temperature plasma doping process is used to modify the surface and grain boundary interface of the heat-treated alloy billet. Trace amounts of rare earth elements Ce and Y are uniformly dispersed into the alloy surface and near-surface grain boundaries. The doping temperature is controlled at 450-500℃, and the doping time is 1.5-2 hours. A vacuum atmosphere ensures no oxidation loss of active elements. The rare earth elements are dispersed at the grain boundaries, purifying them, strengthening grain boundary bonding, and inhibiting grain boundary slip and crack initiation under high-temperature conditions. Simultaneously, during subsequent oxidation, the rare earth elements can segregate at the oxide film-substrate interface, improving oxide film adhesion, reducing internal stress, and solving the problem of easy peeling of traditional alloy oxide films, thus solidifying the foundation for an anti-oxidation interface. S6: High-temperature pre-oxidation and shaping to build a dense protective oxide film. The interface-modified alloy is placed in a controlled atmosphere furnace for constant-temperature pre-oxidation and shaping treatment. This simulates high-temperature service conditions and builds a stable protective oxide film in advance. The oxidation temperature is controlled at 850-900℃, and the oxidation atmosphere is air + trace water vapor. The temperature is maintained for 3-4 hours. Under the induction of active sites, the Cr and Al elements on the alloy surface undergo rapid selective oxidation to generate a composite oxide film with continuous and dense Al2O3 and Cr2O3 as the core, doped with rare earth oxides and SiO2. The film thickness is controlled at 10-15 μm, without pores or cracks, and tightly bonded to the substrate. The pre-oxidation process can eliminate residual stress on the alloy surface, allowing the oxide film to adapt to high-temperature conditions in advance, avoiding disordered growth, cracking and peeling of the oxide film during actual service, and achieving long-term anti-oxidation. S7: Low-temperature stress-relief finishing stabilizes the overall performance of the alloy. The pre-oxidized alloy undergoes low-temperature stress-relief annealing finishing, with the temperature raised to 300-350℃ and held for 1-1.5 hours. It is then slowly cooled to room temperature in the furnace to completely eliminate residual internal stress generated during the melting, solidification, heat treatment, and pre-oxidation processes. This prevents deformation and cracking of the alloy during service due to internal stress. After finishing, the alloy surface is polished to remove the loose oxide layer and retain a dense protective oxide film. The final product is an alloy with uniform structure, strength and toughness, and excellent oxidation and wear resistance, ensuring batch stability and service reliability. Low-temperature stress-relief finishing requires strict control over every detail and must be carried out entirely within a vacuum heat treatment furnace, where the vacuum level must be maintained stably at 10°C. - Heating in an oxygen-containing air atmosphere is strictly prohibited above Pa to prevent oxidation and erosion of the dense protective oxide film on the alloy surface. The heating rate must be strictly controlled at 3-5℃ / min, using a step-by-step slow heating method. Rapid heating is prohibited to avoid causing secondary thermal stress. During the holding stage, the temperature difference inside the furnace must be kept below 5℃ to ensure uniform stress relief in the alloy billet. During the cooling stage, the billet must be cooled slowly with the furnace. Air cooling and water cooling are strictly prohibited. The billet must be removed from the furnace only when the furnace temperature drops below 100℃ to avoid sudden cooling causing new internal stress that could lead to deformation and cracking. For subsequent grinding and polishing, use diamond sandpaper with a fine grit of 800 grit or higher and use a unidirectional light polishing method to remove only the loose surface slag. Excessive grinding is strictly prohibited to avoid damaging the protective oxide film. After finishing, the alloy should be promptly placed in a dry and light-proof environment for storage. The integrity of the surface oxide film should be checked for each piece, and damaged or deformed unqualified pieces should be rejected. Strict quality control of finished batches is required to ensure the stability of the alloy in subsequent service.

[0022] The gradient heating is controlled at 1500-1600℃ for 30-40 min and 1400-1450℃ respectively. The solidification temperature gradient is controlled at 50-80℃ / cm, the solidification rate is controlled at 5-10mm / min, and the water vapor content is 5%-8%.

[0023] The working principle of the synthesis method for high-performance oxidation-resistant and wear-resistant alloys provided by this invention is as follows: Through multi-component compounding and purification pretreatment, the purity of raw materials is strictly controlled, impurities are removed, and structural defects are avoided, laying a solid foundation for uniform alloying. Vacuum gradient staged melting achieves stepwise melting and diffusion of high and low melting point elements, eliminating component segregation and ensuring uniform composition of the alloy liquid. Directional temperature-controlled solidification, with the help of gradient heat dissipation and lattice distortion effect, inhibits grain coarsening, refines the matrix to the submicron level, reduces structural defects, and improves matrix density and grain boundary bonding. Two-stage vacuum heat treatment induces in-situ dispersion precipitation of nano-scale composite hard phases, which not only enhances wear resistance but also alleviates matrix brittleness, achieving a balance between strength and toughness. Low-temperature plasma doping causes rare earth active elements to disperse and distribute in the grain boundaries and surface. The process involves purifying grain boundaries and strengthening interfacial bonding, while simultaneously optimizing the interfacial adhesion between the oxide film and the substrate, reducing internal stress within the film, and inducing selective oxidation of Cr and Al elements on the alloy surface through high-temperature pre-oxidation shaping. This rapidly generates a continuous and dense composite anti-oxidation film, blocking oxygen atom diffusion channels and preventing film cracking and peeling. Low-temperature stress-relief finishing eliminates residual stress throughout the process, stabilizing the alloy's microstructure and properties. The entire process, through the coupling of multiple mechanisms including grain refinement, dispersion strengthening, and interfacial strengthening, simultaneously achieves substrate toughening, oxide film densification, and friction interface self-optimization, solving the problem of imbalance between wear resistance and oxidation resistance, and ensuring long-term stable service of the alloy under high-temperature and high-load composite conditions.

[0024] Compared with related technologies, the synthesis method of high-performance oxidation-resistant and wear-resistant alloy provided by the present invention has the following beneficial effects: This method achieves an alloy hardness of 65-72 HRC, with 85% hardness retention at 800℃, a friction coefficient below 0.25, a wear rate reduced by over 60% compared to traditional alloys, and a high-temperature oxidation weight gain rate reduced by over 70%. The composite oxide film exhibits no cracking or peeling after hundreds of cycles from room temperature to 900℃. It is suitable for extreme working conditions involving high temperature, high load, and oxidation wear, achieving a synergistic improvement in wear resistance and oxidation resistance. The alloy matrix grains are refined to submicron level, with uniformly dispersed reinforcing phases, clean and robust grain boundaries, and a density of 99.5%, free from defects such as segregation and porosity, effectively suppressing… Oxygen diffusion and wear crack propagation are reduced, resulting in a service life more than twice that of traditional alloys, significantly reducing equipment maintenance costs. This process uses conventional equipment without complex intelligent systems, and the process parameters are highly controllable, effectively avoiding problems such as compositional segregation and microstructural defects. The alloy batch performance fluctuation is 3%, balancing feasibility and economy, and is suitable for laboratory research and development as well as industrial mass production. In addition, the alloy achieves a balance between strength and toughness through multiple strengthening mechanisms, and its impact toughness meets the standards for high-end materials. It can be used in metallurgical rolls, mechanical wear-resistant parts, and is also suitable for high-end fields such as aerospace, nuclear power, and high-temperature valves, greatly expanding its application scenarios.

[0025] Second Embodiment Please refer to the following: Figures 2-3 - Figures 4-5 - Figure 6 , Figure 2 A schematic diagram of the structure of a second embodiment of the synthesis method of the high-performance anti-oxidation and wear-resistant alloy provided by the present invention; Figure 3 A schematic diagram of the installation structure is provided for this invention; Figure 4 A schematic diagram of the connecting pipe is provided for this invention; Figure 5 Provided for the present invention Figure 4 An enlarged view of point A shown; Figure 6 Provided for the present invention Figure 4 The enlarged view at point B shows a method for synthesizing a high-performance oxidation-resistant and wear-resistant alloy based on the first embodiment of this application. The second embodiment of this application proposes another method for synthesizing such an alloy. The second embodiment is merely a preferred embodiment of the first embodiment, and its implementation will not affect the independent implementation of the first embodiment.

[0026] Specifically, the difference in the synthesis method of the high-performance anti-oxidation and wear-resistant alloy provided in the second embodiment of this application is that the vacuum induction melting furnace used in S2 of the synthesis method of the high-performance anti-oxidation and wear-resistant alloy includes: mounting base 1; Vacuum grading melting assembly 12, the vacuum grading melting assembly 12 is mounted on the top of the mounting base 1 via a bracket 5, the top of the vacuum grading melting assembly 12 is equipped with a top cover 10, and the bottom of the vacuum grading melting assembly 12 is equipped with a discharge assembly 13. The shape of the vacuum staged melting assembly 12 can be referenced. Figure 2 Vacuum equipment inlets and outlets are installed on the top of the top cover 10 and the outer surface of the vacuum grading melting assembly 12, which can maintain the vacuum condition inside the vacuum grading melting assembly 12.

[0027] Please refer to Figure 2 and Figure 3 The top of the mounting base 1 is equipped with a control box 2 with a door 3. An operation panel 4 is installed on one side of the control box 2. The mounting base 1 includes a base plate 101, a mounting structure 102 and an adjustment structure 103. The mounting structure 102 is used to install the adjustment structure 103 at the bottom of the base plate 101. The threaded connection between the mounting structure 102 and the adjustment structure 103 allows for adjustment of the stability of the base plate 101 as needed, while the operation panel 4 allows for setting of equipment operating parameters.

[0028] Please refer to Figure 2 Monitoring components 9 are installed on the top of the top cover 10 and the outer surface of the vacuum grading melting assembly 12. Heating equipment 11 is installed on the outer surface of the vacuum grading melting assembly 12. Temperature control equipment 14 is installed on the top of the mounting base 1. The temperature control device 14 can independently control the operation and temperature of the heating device 11 on the outer surface of the vacuum grading melting assembly 12, and the monitoring component 9 can monitor the temperature and humidity changes inside the vacuum grading melting assembly 12.

[0029] Please refer to Figure 2 and Figure 3 The top of the top cover 10 is equipped with a second feed pipe 8, the outer surface of the vacuum grading melting assembly 12 is equipped with a first feed pipe 6, and the discharge assembly 13 includes a valve 131 and a discharge pipe 132. The valve 131 is used to install the discharge pipe 132 at the bottom of the vacuum grading melting assembly 12. Valve 131 is made of high temperature resistant material, and the feed pipe can realize separate feeding. The feed pipe is also equipped with a valve.

[0030] Please refer to Figure 2 and Figure 4 The vacuum grading melting assembly 12 includes a first melting chamber 121, a connecting pipe 122, a second melting chamber 123, and a sealing structure 124. The connecting pipe 122 is used to install the first melting chamber 121 on the top of the second melting chamber 123, and the sealing structure 124 is installed on the outer surface of the connecting pipe 122. The sealing structure 124 is used to ensure the sealing of the connection between the rotating shaft 153 and the connecting pipe 122, but does not affect the rotation of the rotating shaft 153.

[0031] Please refer to Figure 2 and Figure 4 The outer surface of the vacuum grading melting assembly 12 is equipped with a driving device 7, and the output end of the driving device 7 is equipped with a separating assembly 15. The dividing component 15 is used to divide the connecting pipe 122 into upper and lower parts. After the dividing component 15 is rotated, the molten raw material can be poured into the interior of the second melting chamber 123.

[0032] Please refer to Figure 2 and Figure 4 The separating assembly 15 includes a separating disk 151, a first sealing ring 152, a rotating shaft 153, and a second sealing ring 154. The rotating shaft 153 is used to mount the separating disk 151 on the output end of the driving device 7, and the first sealing ring 152 and the second sealing ring 154 are mounted on the inner surface of the connecting pipe 122. The first sealing ring 152 and the second sealing ring 154 and the top and bottom of the partition disk 151 are misaligned, which does not affect the rotation of the partition disk 151 but ensures the sealing performance. All partition components 15 are made of high temperature resistant materials.

[0033] Please refer to Figure 4 and Figure 6The monitoring component 9 includes a fixed base 901 and a monitoring device 902. The fixed base 901 is used to install the monitoring device 902 on the top of the top cover 10 or on the outer surface of the vacuum grading melting component 12. The monitoring device 902 includes temperature and humidity monitoring equipment that can monitor the environment inside the vacuum grading melting assembly 12.

[0034] Compared with related technologies, the synthesis method of high-performance oxidation-resistant and wear-resistant alloy provided by the present invention has the following beneficial effects: To improve the melting effect of various materials in the process of producing high-performance oxidation-resistant and wear-resistant alloys, a complete melting furnace is constructed by a first melting chamber 121, a connecting pipe 122, and a second melting chamber 123. Combined with the first feed pipe 6 and the second feed pipe 8, materials with different melting temperatures can be melted separately. Furthermore, the melting temperature can be controlled by two heating devices 11 and a monitoring component 9, thereby increasing the melting effect of different materials and improving the performance of the high-performance oxidation-resistant and wear-resistant alloy. During operation, the furnace body is first closed and evacuated to below 10 Pa, then argon gas is introduced for protection. The temperatures of the upper and lower heating zones are controlled by the two heating devices 11 to form a fixed temperature gradient of 1500-1600℃ for the upper layer and 1400-1450℃ for the lower layer. The heat insulation baffles prevent... The two zones are interconnected to maintain a stable temperature field. High-melting-point raw materials such as Nb, Ti, and Cr are fed into the high-temperature zone through the first feed pipe 6 and kept at a constant temperature to ensure complete melting. Then, low-melting-point raw materials such as Ni, Al, and rare earth elements are fed into the medium-temperature zone through the second feed pipe 8 to avoid high-temperature burn-off and accelerate element diffusion and mixing. The temperature field is monitored throughout the process by the monitoring component 9, and the heating power is manually fine-tuned to ensure precise and controllable melting temperature. Finally, a uniform alloy initial melt without segregation is obtained. This design achieves zoned gradient heating and step-by-step feeding, which can reduce the burn-off of low-melting-point elements, reduce melt splashing, improve safety and melting uniformity, stabilize the temperature field, and ensure precise temperature control. It also reduces batch fluctuations, improves alloy density, uniformity, and overall performance, reduces energy consumption, and increases efficiency.

[0035] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for synthesizing a high-performance oxidation-resistant and wear-resistant alloy, characterized in that, Includes the following steps: S1: Multi-component compounding and pretreatment purification. Fe, Ni, and Co are the main matrix elements, combined with Cr and Al as the core antioxidant elements, and Nb, Ti, and B are added as wear-resistant strengthening elements. Trace amounts of rare earth Ce, Y, and Si are added as interface modification and oxide film control elements. The purity of each element is strictly controlled to 99.95% to avoid the introduction of impurities that induce structural defects. After being accurately weighed according to the preset composition ratio, the metal raw materials are sequentially pickled to remove oxide scale, ultrasonically cleaned with anhydrous ethanol, and vacuum dried to remove surface oil, oxide impurities, and moisture. At the same time, rare earth elements are vacuum-sealed for pretreatment to prevent oxidation and burn-off during the melting process, ensuring the accuracy and uniformity of the subsequent alloy composition and laying the foundation for subsequent uniform alloying. S2: Vacuum gradient staged melting to achieve homogenization of the initial melt. Pre-treated raw materials are loaded into the vacuum induction melting furnace in the order of adding high-melting-point refractory elements first, followed by low-melting-point easily fusible elements. After the furnace is closed, a vacuum of 10... - Below Pa, high-purity argon is introduced as a protective gas to prevent the oxidation of alloying elements during the melting process. A gradient heating staged melting mode is adopted to fully melt and diffuse high-melting-point Nb, Ti, and Cr elements. After cooling, low-melting-point Ni, Al, and rare earth elements are added and held at the temperature for 20-30 minutes. S3: Directional temperature-controlled solidification refines the matrix grain structure. The homogenized alloy initial melt is rapidly transferred to a directional solidification mold. A temperature-controlled solidification process coupled with slow cooling and directional heat dissipation is used to control the solidification temperature gradient and solidification rate, avoiding internal stress concentration and loose structure caused by rapid solidification. Directional heat dissipation guides the grains to grow in a single direction. Combined with the high entropy effect of the alloy system, excessive growth of columnar crystals is suppressed, and the matrix grains are refined to the submicron level. At the same time, it promotes the in-situ uniform precipitation of strengthening phases, reduces grain boundary defects and shrinkage porosity, and improves the matrix density and grain boundary bonding strength, providing a high-quality microstructure for subsequent strengthening and modification. S4: In-situ composite strengthening phase regulation precipitation. The solidified alloy billet is transferred to a vacuum heat treatment furnace for two-stage isothermal heat treatment to regulate the morphology and distribution of the strengthening phase. The first stage is low-temperature pretreatment: the temperature is raised to 600-650℃ and held for 2-3 hours to eliminate the internal stress of the alloy solidification and stabilize the matrix structure. The second stage is high-temperature aging treatment: the temperature is raised to 900-950℃ and held for 4-5 hours to induce the full reaction of C, B, Ti, and Nb elements inside the alloy, and to generate nano-scale TiC, NbB2, and Cr7C3 composite hard phases in situ. The aging temperature and time are strictly controlled to avoid the aggregation and coarsening of the strengthening phase, so that the hard phase is uniformly dispersed in the matrix grains and grain boundaries. This not only greatly improves the hardness and wear resistance of the alloy, but also avoids the increase in matrix brittleness caused by excessive precipitation of hard phase, thus achieving synergistic optimization of wear resistance and toughness. S5: Active element interface dispersion modification. A low-temperature plasma doping process is used to modify the surface and grain boundary interface of the heat-treated alloy billet. Trace amounts of rare earth elements Ce and Y are uniformly dispersed into the alloy surface and near-surface grain boundaries. The doping temperature is controlled at 450-500℃, and the doping time is 1.5-2 hours. A vacuum atmosphere ensures no oxidation loss of active elements. The rare earth elements are dispersed at the grain boundaries, purifying them, strengthening grain boundary bonding, and inhibiting grain boundary slip and crack initiation under high-temperature conditions. Simultaneously, during subsequent oxidation, the rare earth elements can segregate at the oxide film-substrate interface, improving oxide film adhesion, reducing internal stress, and solving the problem of easy peeling of traditional alloy oxide films, thus solidifying the foundation for an anti-oxidation interface. S6: High-temperature pre-oxidation and shaping to build a dense protective oxide film. The interface-modified alloy is placed in a controlled atmosphere furnace for constant-temperature pre-oxidation and shaping treatment. This simulates high-temperature service conditions and builds a stable protective oxide film in advance. The oxidation temperature is controlled at 850-900℃, and the oxidation atmosphere is air + trace water vapor. The temperature is maintained for 3-4 hours. Under the induction of active sites, the Cr and Al elements on the alloy surface undergo rapid selective oxidation to generate a composite oxide film with continuous and dense Al2O3 and Cr2O3 as the core, doped with rare earth oxides and SiO2. The film thickness is controlled at 10-15 μm, without pores or cracks, and tightly bonded to the substrate. The pre-oxidation process can eliminate residual stress on the alloy surface, allowing the oxide film to adapt to high-temperature conditions in advance, avoiding disordered growth, cracking and peeling of the oxide film during actual service, and achieving long-term anti-oxidation. S7: Low-temperature stress-relief finishing stabilizes the overall performance of the alloy. The pre-oxidized alloy undergoes low-temperature stress-relief annealing finishing, with the temperature raised to 300-350℃ and held for 1-1.5 hours. It is then slowly cooled to room temperature in the furnace to completely eliminate residual internal stress generated during the melting, solidification, heat treatment, and pre-oxidation processes. This prevents deformation and cracking of the alloy during service due to internal stress. After finishing, the alloy surface is polished to remove the loose oxide layer and retain a dense protective oxide film. The final product is an alloy with uniform structure, strength and toughness, and excellent oxidation and wear resistance, ensuring batch stability and service reliability.

2. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 1, characterized in that, The gradient heating is controlled at 1500-1600℃ for 30-40 min and 1400-1450℃ respectively. The solidification temperature gradient is controlled at 50-80℃ / cm, the solidification rate is controlled at 5-10mm / min, and the water vapor content is 5%-8%.

3. The method for synthesizing high-performance oxidation-resistant and wear-resistant alloys according to claim 1, wherein the vacuum induction melting furnace used in step S2 is characterized in that, include: Install the base frame; A vacuum grading melting assembly is mounted on top of a mounting base via a bracket. A top cover is installed on the top of the vacuum grading melting assembly, and a discharge assembly is installed at the bottom of the vacuum grading melting assembly.

4. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 3, characterized in that, A control box with a door is installed on the top of the mounting base. An operation panel is installed on one side of the control box. The mounting base includes a base plate, a mounting structure, and an adjustment structure. The mounting structure is used to install the adjustment structure on the bottom of the base plate.

5. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 3, characterized in that, Monitoring components are installed on the top of the top cover and the outer surface of the vacuum grading melting assembly. Heating equipment is installed on the outer surface of the vacuum grading melting assembly, and temperature control equipment is installed on the top of the mounting base.

6. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 1, characterized in that, A second feed pipe is installed on the top of the top cover, a first feed pipe is installed on the outer surface of the vacuum grading melting assembly, and the discharge assembly includes a valve and a discharge pipe, wherein the valve is used to install the discharge pipe at the bottom of the vacuum grading melting assembly.

7. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 3, characterized in that, The vacuum grading melting assembly includes a first melting chamber, a connecting pipe, a second melting chamber, and a sealing structure. The connecting pipe is used to install the first melting chamber on top of the second melting chamber, and the sealing structure is installed on the outer surface of the connecting pipe.

8. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 3, characterized in that, A drive device is installed on the outer surface of the vacuum grading melting assembly, and a separator is installed at the output end of the drive device.

9. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 8, characterized in that, The separating assembly includes a separating disk, a first sealing ring, a rotating shaft, and a second sealing ring. The rotating shaft is used to mount the separating disk at the output end of the drive device, and the first and second sealing rings are mounted on the inner surface of the connecting pipe.

10. The method for synthesizing the high-performance oxidation-resistant and wear-resistant alloy according to claim 3, characterized in that, The monitoring component includes a fixed base and a monitoring device. The fixed base is used to mount the monitoring device on the top of the top cover or on the outer surface of the vacuum grading melting component.

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