Method for manufacturing iron-based alloy ceramic composite wear-resistant material by high temperature and high pressure die casting

Abstract

The application discloses a method for manufacturing an iron-based alloy ceramic composite wear-resistant material by a high-temperature and high-pressure die casting method, and comprises the following steps: S1, preparing a ceramic preform; S2, heating iron-based alloy liquid to 1620 DEG C, and pressing the iron-based alloy liquid into the ceramic preform by a press machine, and keeping the pressure for 2 minutes; then, cooling and forming, and taking out after being kept in a holding furnace for 12-24 hours, and obtaining the composite wear-resistant material after being cooled to normal temperature; and S3, performing heat treatment on the material obtained in the step S2. The application can produce a new composite material, i.e., an iron-based ceramic composite wear-resistant material, which simultaneously considers various performances of the wear-resistant material and greatly improves the comprehensive performance of the product, smelts higher than a traditional smelting temperature, and uses liquid lead as a coolant to cooperate with a composite material mold, so that the cooling effect meets the process requirement.

Description

Technical Field

[0001] This invention relates to the field of wear-resistant materials technology, specifically a method for manufacturing iron-based alloy ceramic composite wear-resistant materials using high-temperature and high-pressure die casting. Background Technology

[0002] Wear-resistant materials are widely used in modern production and daily life. For example, grinding systems in various vertical mills, hammers, plates, and liners in crushers, and various chutes in mines all require large quantities of wear-resistant materials. Currently, the most widely used metallic materials are still high-manganese steel and chromium alloy steel, which are characterized by their strength and toughness, but are prone to plastic deformation and are not wear-resistant. Alloy steels have excellent mechanical properties and high wear resistance, but poor toughness. Wear-resistant white cast iron has high wear resistance, but low toughness and high cost. Composite materials include bimetallic composites, inlaid alloy composites, and metal-matrix ceramic composites, which have good wear resistance and high toughness, but suffer from complex manufacturing processes. Non-metallic materials include rubber or rubber-like materials, ceramics, etc.

[0003] However, each of the above materials has its own advantages and disadvantages. For example, metal materials are impact-resistant but not wear-resistant, ceramics are wear-resistant but not impact-resistant, and rubber materials are corrosion-resistant but have low strength and are easily deformed. For example, Chinese patent CN 109022869 A discloses a high-alloy matrix metal-ceramic composite material and its preparation method. The high-alloy matrix metal-ceramic composite material has the following volume ratio: high-alloy matrix material: metal-ceramic reinforcing particles = (1~10):1; high-alloy matrix material C: 1~8%; main alloying elements: Ni: 0~60%, Mo: 0~60%, Cr: 0~40%, Mn: 0~30%, V: 0~20%, Ti: 0~20%, W: 0~15%, Nb: 0~15%; trace elements are one or more of B, Si, Zr, Cu, Co, Al and rare earth elements; the balance is Fe and unavoidable impurities. The preparation method adopts a programmed temperature-controlled liquid phase sintering method. The sintering process is as follows: heat up to 800-900℃ at a rate of 1-10℃ / min and hold for 30-60min; heat up to 1150-1650℃ at a rate of 1-6℃ / min and hold for 3-20h, then cool with the furnace. It can be used directly for wear-resistant materials, or it can be used for wear-resistant materials after subsequent heat treatment.

[0004] Smelting temperature affects the fluidity of liquid iron-based alloys, while high temperatures also make cooling the molding die difficult. To address this, we propose a novel preparation process where the smelting temperature exceeds traditional smelting temperatures. This ensures the high fluidity of the iron-based alloy while effectively cooling the mold with molten lead, allowing the composite mold to maintain its strength even at high temperatures. Summary of the Invention

[0005] The purpose of this invention is to provide a method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting. This method can produce a new type of composite material—a metal-based ceramic composite wear-resistant material—that simultaneously takes into account the various properties of wear-resistant materials and can greatly improve the overall performance of the product. The metal matrix uses an iron-based alloy as a carrier, and the ceramic uses alumina or zirconium alumina as a wear-resistant reinforcing matrix to form a super wear-resistant material, thereby solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting, comprising the following steps:

[0007] S1. Preparation of ceramic preforms;

[0008] S2. Iron-based alloy liquid is injected into the ceramic preform and cooled to obtain a composite wear-resistant material.

[0009] S3. Heat treat the material obtained in step S2.

[0010] Preferably, step S1 includes the following steps:

[0011] S1.1 Ceramic particle pretreatment: Ceramic particles are ground in a grinder, washed and sieved to remove fine powder, and then dried to obtain ceramic particles with a particle size of 1.3mm-1.8mm.

[0012] S1.2 Preparation of ceramic particle mixture: The ceramic particles obtained in step S1.1 are mixed with binder, activator and foam particles, wherein the volume ratio of the ceramic particles is 20-50%; wherein the activator is aluminum powder, magnesium powder, silicon carbide powder, tungsten carbide powder, and alumina powder, zirconium oxide powder and inorganic salt colloid for bonding, in a mass ratio of 1:1:25:30:12:18:13.

[0013] S1.3. After the mixture in step S1.2 is shaped by a mold, it is sintered at high temperature to obtain a ceramic preform.

[0014] Preferably, in step S1.3, the mixture is heated to 450°C-550°C using a resistance furnace, sintered for 6-10 hours, and then cooled to room temperature.

[0015] Preferably, in step S2, the iron-based alloy liquid is heated to 1620℃-1720℃ and pressed into the ceramic preform by a press at a pressure of 1-10 MPa for 2-5 minutes; then cooled and shaped, placed in a heat preservation furnace for 24 hours, and then taken out and cooled to room temperature.

[0016] Preferably, the iron-based alloy in step S2 comprises the following elemental composition: C: 2.5%-3.5%, Si: 0.8%-1.5%, Mn: 1.8%-2.5%, Cr: 26%-27%, Mo: 0.7%-1.0%, W: 0.9%-1.3%, Ni: 0.3%-0.5%, P: 0-0.1%, and S: 0-0.06%.

[0017] Preferably, the ceramic particles in step S1.1 are one or more of alumina, zirconium oxide, and zirconium alumina.

[0018] Preferably, the mold in step S1.3 is made of a composite material of copper, heat-resistant steel and ceramic, and liquid lead is used as a coolant to improve the cooling effect.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] 1. This invention uses a ceramic mixture prepared from ceramic particles, foam particles, activator and binder, and controls the volume ratio of ceramic particles to 20-50%, which improves the pore structure of the ceramic sponge block, increases the wettability of the ceramic particle surface, reduces the difficulty of subsequent processes, and makes it easier for iron-based alloys to undergo high-temperature melting and infiltration.

[0021] 2. This invention uses both iron-based alloy and ceramic preform as materials. After melting the iron-based alloy, it is infiltrated into the pores of the ceramic preform, thus combining the wear resistance of ceramics with the toughness of iron-based alloy, and also has extremely high corrosion resistance.

[0022] 3. In this invention, the ceramic preform is preheated in a composite mold, and then the iron-based alloy is melted and infiltrated under high temperature and high pressure under the action of a press. This improves the ability of the iron-based alloy liquid to penetrate into the pores of the ceramic preform particles, and increases the bonding strength between the ceramic particles and the iron-based alloy as well as the overall strength of the preform.

[0023] 4. The smelting temperature of this invention is higher than that of traditional smelting and the casting pressure is higher than that of traditional casting. By using liquid lead as a coolant in conjunction with composite material molds, the cooling effect meets the process requirements. Attached Figure Description

[0024] Figure 1 This is a flowchart of the method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting according to the present invention.

[0025] Figure 2 This is a schematic cross-sectional view of the mold structure in an embodiment of the present invention;

[0026] Figure 3 This is a cross-sectional comparison diagram of the product of this invention and a traditional product;

[0027] Figure 4The results of the bending resistance test of the product of this invention are shown. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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.

[0029] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] Example 1

[0031] Please see Figure 1 This invention provides a technical solution: a method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting, comprising the following steps:

[0032] S1. Preparation of ceramic preforms:

[0033] S1.1 Ceramic particle pretreatment: Ceramic particles are ground in a grinder, washed and sieved to remove fine powder, and then dried to obtain ceramic particles with a particle size of 1.3mm-1.8mm.

[0034] S1.2 Preparation of ceramic particle mixture: The ceramic particles obtained in step S1.1 are mixed with binder, activator and foam particles, wherein the volume ratio of ceramic particles is 20-50%; wherein the activator is aluminum powder, magnesium powder, silicon carbide powder, tungsten carbide powder, and alumina powder, zirconium oxide powder and inorganic salt colloid for bonding, in a mass ratio of 1:1:25:30:12:18:13.

[0035] S1.3. Place the mixture from step S1.2 into a mold, heat the mixture to 450°C using a resistance furnace, sinter for 6 hours, and then cool and shape it.

[0036] S2. Heat the iron-based alloy liquid to 1620℃ and press it into the ceramic preform using a press at a pressure of 1MP for 2 minutes. Then cool and solidify it, place it in a heat preservation furnace and keep it at a temperature for 12 hours. After cooling to room temperature, the composite wear-resistant material is obtained.

[0037] S3. The material obtained in step S2 is subjected to quenching treatment.

[0038] The iron-based alloy in step S2 comprises the following elemental composition: C: 2.5%, Si: 0.8%, Mn: 1.8%, Cr: 26%, Mo: 0.7%, W: 0.9%, Ni: 0.3%, P: 0.1%, and S: 0.06%.

[0039] The ceramic particles in step S1.1 are one or more of alumina, zirconium oxide, and zirconium alumina.

[0040] Example 2

[0041] Please see Figure 1 This invention provides a technical solution: a method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting, comprising the following steps:

[0042] S1. Preparation of ceramic preforms; S1.1. Pretreatment of ceramic particles: Ceramic particles are ground in a grinder, washed and sieved to remove fine powder, and then dried to obtain ceramic particles with a particle size of 1.3mm-1.8mm.

[0043] S1.2 Preparation of ceramic particle mixture: The ceramic particles obtained in step S1.1 are mixed with binder, activator and foam particles, wherein the volume ratio of ceramic particles is 50%; wherein the activator is aluminum powder, magnesium powder, silicon carbide powder, tungsten carbide powder, and alumina powder, zirconium oxide powder and inorganic salt colloid for bonding, in a mass ratio of 1:1:25:30:12:18:13.

[0044] S1.3. The mixture from step S1.2 is heated to 500°C using a resistance furnace, sintered for 8 hours, and then cooled to room temperature to obtain a ceramic preform.

[0045] S2. Heat the iron-based alloy liquid to 1650℃ and press it into the ceramic preform using a press. Maintain the pressure at 10MP for 3 minutes. Then cool and solidify it. Place it in a heat preservation furnace and keep it at the temperature for 12 hours. Remove it and cool it to room temperature to obtain the composite wear-resistant material.

[0046] S3. Heat treat the material obtained in step S2.

[0047] The iron-based alloy in step S2 comprises the following elemental composition: C: 3.5%, Si: 1.5%, Mn: 12.5%, Cr: 27%, Mo: 1.0%, W: 1.3%, Ni: 0.5%, P: 0.1%, and S: 0.06%.

[0048] The ceramic particles in step S1.1 are one or more of alumina, zirconium oxide, and zirconium alumina.

[0049] Example 3

[0050] Please see Figure 1 This invention provides a technical solution: a method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting, comprising the following steps:

[0051] S1. Preparation of ceramic preforms: S1.1. Pretreatment of ceramic particles: Ceramic particles are ground in a grinder, washed and sieved to remove fine powder, and then dried to obtain ceramic particles with a particle size of 1.3 mm.

[0052] S1.2 Preparation of ceramic particle mixture: The ceramic particles obtained in step S1.1 are mixed with binder, activator and foam particles, wherein the volume ratio of ceramic particles is 50%; wherein the activator is aluminum powder, magnesium powder, silicon carbide powder, tungsten carbide powder, and alumina powder, zirconium oxide powder and inorganic salt colloid for bonding, in a mass ratio of 1:1:25:30:12:18:13.

[0053] S1.3. After the mixture in step S1.2 is shaped by a mold, it is sintered at high temperature to obtain a ceramic preform;

[0054] S2. Iron-based alloy liquid is injected into the ceramic preform and cooled to obtain a composite wear-resistant material.

[0055] S3. Heat treat the material obtained in step S2.

[0056] In step S1.3, the mixture is heated to 550°C using a resistance furnace, sintered for 10 hours, and then cooled to room temperature.

[0057] In step S2, the iron-based alloy liquid is heated to 1700°C and pressed into the ceramic preform by a press at a pressure of 8 MPa for 5 minutes. Then it is cooled and shaped, placed in a heat preservation furnace for 24 hours, and then taken out and cooled to room temperature.

[0058] The iron-based alloy in step S2 comprises the following elemental composition: C: 3.5%, Si: 1.5%, Mn: 2.5%, Cr: 27%, Mo: 1.0%, W: 1.3%, Ni: 0.5%, P: 0.1%, and S: 0.06%.

[0059] The ceramic particles in step S1.1 are one or more of alumina, zirconium oxide, and zirconium alumina.

[0060] It should be noted that in actual use, users can choose the shape and structure of the mold according to the actual situation. This article only presents a mold structure in one embodiment.

[0061] Working principle:

[0062] In the process of ceramics being composited with metals, the low bonding strength between the metal and ceramics is a problem. Furthermore, the inability of the molten metal to completely penetrate the pores of the ceramic particles causes product defects, severely affecting product performance and lifespan. A solution is to apply high pressure using a press to force the molten metal into a composite mold, filling the pores of the ceramic preform within the mold with the molten metal. For example... Figure 3 As shown, castings formed under high pressure have increased metal density and finer metal particles, effectively improving the physical properties of the metal, increasing its strength and toughness. The metal also better encapsulates the ceramic particles, resulting in a higher bonding strength between the metal and ceramic, thus giving the product excellent impact resistance and toughness (e.g., ...). Figure 4 As shown in the figure, it also has the high wear resistance of ceramics.

[0063] Lead and lead alloys are liquefied at 420°C, and a temperature control system maintains the molten lead at temperatures below 1000°C, ensuring good fluidity without boiling or evaporation. The high thermal conductivity of molten lead makes it safe and reliable (unlike water, which can instantly generate high-temperature steam and explode uncontrollably). It quickly conducts heat away from the mold, acting as a coolant. Copper, with its excellent thermal conductivity and high melting point, is a good conductor, while heat-resistant steel has poor thermal conductivity. Molds combining copper and heat-resistant steel combine the advantages of both. When cooled in a lead bath, the molds produced from this composite material cool rapidly and safely, simultaneously achieving preheating and insulation. Combined with liquid lead, this meets the requirements of mold cooling processes.

[0064] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0065] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting, characterized in that, Includes the following steps: S1. Preparation of ceramic preforms, specifically: S1.1 Ceramic particle pretreatment: Ceramic particles are ground in a grinder, washed and sieved to remove fine powder, and then dried to obtain ceramic particles with a particle size of 1.3mm-1.8mm. S1.2 Preparation of ceramic particle mixture: The ceramic particles obtained in step S1.1 are mixed with binder, activator and foam particles, wherein the volume ratio of the ceramic particles is 20-50%; wherein the activator is aluminum powder, magnesium powder, silicon carbide powder, tungsten carbide powder, and alumina powder, zirconium oxide powder and inorganic salt colloid for bonding, in a mass ratio of 1:1:25:30:12:18:13; S1.

3. After the mixture in step S1.2 is shaped by a mold, it is sintered at high temperature to obtain a ceramic preform; S2. Injecting iron-based alloy liquid into the ceramic preform and cooling it to obtain a composite wear-resistant material. Specifically, the iron-based alloy liquid is heated to 1620℃-1700℃ and pressed into the ceramic preform by a press at a pressure of 1-10MP for 2-5 minutes. Then it is cooled and shaped, placed in a heat preservation furnace for 12-24 hours, and then taken out and cooled to room temperature. The iron-based alloys contain the following elemental compositions: C: 2.5%-3.5%, Si: 0.8%-1.5%, Mn: 1.8%-2.5%, Cr: 26%-27%, Mo: 0.7%-1.0%, W: 0.9%-1.3%, Ni: 0.3%-0.5%, P: 0-0.1%, and S: 0-0.06%. S3. Heat treat the material obtained in step S2.

2. The method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting according to claim 1, characterized in that: In step S1.3, the mixture is heated to 450℃-550℃ using a resistance furnace, sintered for 6-10 hours, and then cooled to room temperature.

3. The method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting according to claim 1, characterized in that: The ceramic particles in step S1.1 are one or more of alumina, zirconium oxide, and zirconium alumina.

4. The method for manufacturing iron-based alloy ceramic composite wear-resistant materials by high-temperature and high-pressure die casting according to claim 1, characterized in that: The mold in step S1.3 is made of a composite material of copper, heat-resistant steel and ceramics, and liquid lead is used as a coolant to improve the cooling effect.

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