Wear-resistant iron-based high-speed electric arc spraying powder core wire and application thereof

Abstract

The application relates to a wear-resistant iron-based high-speed electric arc spraying powder core wire and application thereof. The wear-resistant iron-based high-speed electric arc spraying powder core wire is composed of a cladding layer and a powder core powder. The formula of the powder core powder comprises the following components in percentage by mass: Mn: 13-16%; Cr: 8-12%; Ni: 5-8%; B: 4-6%; Nb: 5-7%; Al: 5-9%; and the balance is Fe. The wire prepared by using the above-mentioned powder core wire ratio is used to prepare a coating on a Q235 steel substrate which is subjected to oil removal, rust removal and sand blasting roughening. A continuous and dense spraying coating can be formed on the Q235 steel substrate, and the spraying coating has good mechanical properties, wear resistance and corrosion resistance, and the coating has low porosity and high hardness.

Description

Technical Field

[0001] This invention relates to the field of composite materials and materials processing engineering technology, and to a wear-resistant iron-based high-speed arc sprayed powder core wire and its application. Background Technology

[0002] In the industrial sector, wear is one of the main failure modes, and the resulting economic losses are significant. With the rapid development of modern industrial technology and the increasing mechanization and automation, the failures and even downtime caused by wear of machinery and its components have attracted widespread attention. Surface treatment technology, as an effective method to improve the wear and corrosion resistance of material surfaces, has been widely used for the protection of component surfaces. High-speed arc spraying technology is one of the important surface technologies. In recent years, with the development of high-speed arc spraying technology, the microstructure and properties of coatings have been further improved, leading to its wider application. High-speed arc spraying technology can prepare high-performance coatings on metal surfaces, effectively improving their surface properties and providing wear and corrosion resistance. It is commonly used for thermal protection or surface protection of some important mechanical components. Fe-based materials are the most widely used materials in high-speed arc spraying due to their low cost and ease of processing. By adding other alloying elements, excellent properties can be obtained.

[0003] Researchers have discovered that adding hard phase elements (such as boron) to Fe-based materials and preparing coatings using high-speed arc spraying technology can significantly improve the wear resistance of the coatings. Their results show that adding hard phase elements B and C can generate hard phases such as Cr2B and Fe2B in FeCr solid solutions. Because these borides are very hard and possess good stability and corrosion resistance, they enhance the mechanical properties of the alloy. Specifically, the hardness, wear resistance, and corrosion resistance of the alloy are 2 to 5 times that of stainless steel. Researchers also investigated the effect of the hard phase element content on the coating's wear resistance. The results indicate that increasing the hard phase element content reduces the amount of wear on the coating, effectively improving its wear resistance. Current research has studied the microstructure of high-speed arc-sprayed Fe-based coatings, revealing a typical layered structure with defects such as oxides and pores between the phase layers. These defects reduce the coating's wear resistance.

[0004] Therefore, it is necessary to develop a wear-resistant iron-based high-speed arc-sprayed powder core wire to solve defects such as oxides and pores and improve wear resistance. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a wear-resistant iron-based high-speed arc sprayed powder core wire material, which can effectively reduce coating porosity, reduce interlayer oxides, and improve the wear resistance of the iron-based high-speed arc sprayed powder core wire material.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: the wear-resistant iron-based high-speed arc sprayed powder core wire is composed of a coating layer and powder core powder. The formula of the powder core powder includes the following by mass percentage: Mn: 13-16%; Cr: 8-12%; Ni: 5-8%; B: 4-6%; Nb: 5-7%; Al: 5-9%; with the balance being Fe.

[0007] By employing the above technical solution, and through the synergistic effect of the properties of Mn, Cr, Ni, B, Nb, Al, and Fe powders, a high-speed arc-sprayed iron-based cored wire with improved mechanical properties, wear resistance, and corrosion resistance was obtained. Fe-based alloy coatings utilize inexpensive raw materials, exhibit good wear resistance, and demonstrate excellent corrosion resistance under medium- and low-temperature conditions and in weakly corrosive media. The addition of B to the cored wire forms interstitial compounds with transition metals, improving the alloy's mechanical properties. The addition of B significantly enhances the coating's hardness. Nb, with its large atomic radius, effectively improves mechanical properties upon addition to the alloy. The addition of Al to the cored wire has been shown to effectively reduce brittleness, increase toughness, and improve machinability, while also exhibiting excellent corrosion resistance. Therefore, its properties can be used as a coating for strengthening substrate surfaces in special environments. Furthermore, adding appropriate amounts of Cr, Ni, and Mn to the Fe-based coating enhances its overall performance, allowing for the design of the wear-resistant coating composition. Under normal temperature and pressure, high manganese (Mn) content is required for workpieces subjected to complex stress conditions, especially those under strong impact, because manganese-containing austenite has strong work hardening ability, which can effectively improve wear resistance. The addition of chromium (Cr) to the powder core forms a dense oxide film, which can prevent oxygen diffusion inward and other elements in the coating from diffusing outward, thereby improving the material's oxidation resistance and corrosion resistance. Simultaneously, Cr can dissolve into the matrix phase to form a solid solution, improving the coating's strength, hardness, and high-temperature resistance. The addition of nitrogen (Ni) to the powder core facilitates the diffusion of the coating metal into the substrate, forming a micro-welded bond, improving the adhesion between the coating and the substrate, significantly increasing the bonding strength. Furthermore, the addition of Ni contributes to improved coating toughness.

[0008] Preferably, the preparation method of the wear-resistant iron-based high-speed arc sprayed powder core wire is as follows: the uniformly mixed powder core is filled into the coating layer, and the coating layer is closed to cover the powder core, and then the wear-resistant iron-based high-speed arc sprayed powder core wire is obtained by drawing the wire through a wire drawing die.

[0009] Preferably, during the preparation process, the powder core powder is obtained by mixing Mn powder, Cr powder, Ni powder, B powder, Nb powder, Al powder and Fe powder weighed according to the formula ratio using a mixer and then sieving it to obtain a uniformly mixed powder core powder.

[0010] Preferably, the coating layer is a 304 stainless steel strip. Before filling the core powder into the coating layer, the 304 stainless steel strip is first tied into a U-shape. After filling the core powder, the U-shaped stainless steel strip is closed, so that the U-shaped stainless steel strip covers the core powder. Then, it is fed into the wire drawing die for drawing and diameter reduction in stages to obtain the core wire.

[0011] Preferably, when the coated stainless steel strip is fed into the drawing die, it is made to pass through drawing dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm and 2.0mm in sequence, and then be drawn and reduced in diameter one by one to obtain powder core wire.

[0012] Preferably, a 304 stainless steel strip with a width of 12mm and a thickness of 0.3mm is tied into a U-shape, and then the uniformly mixed core powder is filled into the U-shaped stainless steel strip at a filling rate of 30% to 32%.

[0013] Preferably, the diameter of the wear-resistant iron-based high-speed arc sprayed powder core wire obtained after drawing is 2mm.

[0014] The technical problem to be solved by this invention is to provide an application of the wear-resistant iron-based high-speed arc sprayed core wire material, that is, the wear-resistant iron-based core wire material coating prepared on the substrate by the high-speed arc spraying method using the wear-resistant iron-based high-speed arc sprayed core wire material can form a continuous and dense sprayed coating. The wear-resistant iron-based core wire material coating has low porosity, high hardness, and good mechanical properties, wear resistance and corrosion resistance.

[0015] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a wear-resistant iron-based high-speed arc spraying powder core wire coating is prepared by using wear-resistant iron-based high-speed arc spraying powder core wire, and the preparation method specifically includes the following steps:

[0016] S1 substrate surface pretreatment: Anhydrous ethanol is used to remove stains and oil stains from the substrate surface, and then iron sand is used to roughen the substrate surface.

[0017] S2 Coating Preparation: Wear-resistant iron-based high-speed arc spraying (HSA) wire is applied to the treated substrate surface using high-speed arc spraying technology to obtain a wear-resistant iron-based HSA wire coating. The purpose of pre-treating the substrate surface is to remove rust and create a uniformly rough surface, improving coating adhesion. By applying HSA wire to the coating using HSA wire, a wear-resistant iron-based HSA wire coating (FeMnCrNiBNbAl coating) can be obtained.

[0018] Preferably, the substrate in step S1 is a Q235 steel substrate; the iron sand used for sandblasting roughening is 16-18 mesh.

[0019] Preferably, the spraying process parameters in step S2 are as follows: air pressure: 0.6–0.7 MPa, spraying voltage: 28–40 V, spraying current: 180–240 A, spraying distance: 150–200 mm; an intermittent spraying method is used, and the spraying is repeated 6–10 times to obtain a wear-resistant iron-based powder core wire coating. The porosity of the wear-resistant iron-based powder core wire coating is ≤2.0%, and the Vickers hardness is 600 HV. 0.1 -800HV 0.1 .

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] (1) This invention adds B, Nb and Al to the formulation of wear-resistant iron-based powder core wire, and through the synergistic effect of the properties of Mn, Cr, Ni, B, Nb, Al and Fe powder, obtains iron-based high-speed arc sprayed powder core wire with better mechanical properties, wear resistance and corrosion resistance; the addition of B element greatly improves the hardness of the coating; Nb element has a large atomic radius, and its addition can effectively improve mechanical properties; the addition of Al element can effectively reduce brittleness and improve toughness, thereby improving machinability, and its corrosion resistance is also relatively good, so it can be used as a coating for strengthening the surface of substrates in special environments; and the alloy powder added to the powder core wire is inexpensive and has a low cost.

[0022] (2) This invention uses high-speed arc spraying technology to prepare a coating, forming a continuous and dense wear-resistant iron-based powder core wire coating (FeMnCrNiBNbAl coating) on ​​a Q235 steel substrate; the high-speed arc spraying technology is simple to operate, convenient and economical to prepare the spraying material, and can achieve in-situ large-area spraying, etc., and has the lowest cost compared with other spraying methods; the wear-resistant iron-based high-speed arc sprayed powder core wire coating with excellent mechanical properties and wear resistance is obtained, which is suitable for parts working under severe wear and other harsh conditions, easy to industrialize, and has broad application prospects;

[0023] (3) Using high-speed arc spraying technology, the coating prepared on the substrate has a porosity of ≤2.0% and a Vickers hardness of 600 HV. 0.1 -800HV 0.1 . Attached Figure Description

[0024] Figure 1 This is a surface SEM image of the wear-resistant iron-based powder core wire coating (FeMnCrNiBNbAl coating) of Specific Embodiment 1 of the present invention;

[0025] Figure 2This is a cross-sectional SEM image of the wear-resistant iron-based powder core wire coating (FeMnCrNiBNbAl coating) of Specific Embodiment 1 of the present invention;

[0026] Figure 3 This is a cross-sectional metallographic image of the wear-resistant iron-based powder core wire coating (FeMnCrNiBNbAl coating) of Specific Embodiment 1 of the present invention;

[0027] Figure 4 This is the EDS elemental distribution result of the cross section of the wear-resistant iron-based powder core wire coating (FeMnCrNiBNbAl coating) in specific embodiment 1 of the present invention;

[0028] Figure 5 This is the surface XRD characterization spectrum of the wear-resistant iron-based powder core wire coating (FeMnCrNiBNbAl coating) of Specific Embodiment 1 of the present invention. Detailed Implementation

[0029] To enhance understanding of the present invention, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. These embodiments are only used to explain the invention and do not limit the scope of protection of the invention.

[0030] To demonstrate the performance of the FeMnCrNiBNbAl coating of this invention, it is compared with the FeMnCrNi coating as a comparative example below.

[0031] Example: The wear-resistant iron-based high-speed arc sprayed core wire is composed of a coating layer and core powder. The core powder formula includes the following by mass percentage: Mn: 13-16%; Cr: 8-12%; Ni: 5-8%; B: 4-6%; Nb: 5-7%; Al: 5-9%; balance Fe.

[0032] The preparation method of this wear-resistant iron-based high-speed arc sprayed powder core wire is as follows: The uniformly mixed powder core is filled into the coating layer, and the coating layer is closed to cover the powder core. The powder core is then drawn into wire using a drawing die to obtain the wear-resistant iron-based high-speed arc sprayed powder core wire. The powder core is obtained by uniformly mixing Mn powder, Cr powder, Ni powder, B powder, Nb powder, Al powder, and Fe powder weighed according to the formula ratio using a mixer, followed by sieving to obtain uniformly mixed powder core. The coating layer is a 304 stainless steel strip. Before filling the coating layer with the powder core, the 304 stainless steel strip is first... 4. A 12mm wide and 0.3mm thick 304 stainless steel strip is tied into a U-shape. The uniformly mixed core powder is then filled into the U-shaped stainless steel strip at a filling rate of 30%–32%. After filling with the core powder, the U-shaped stainless steel strip is closed, thus covering the core powder. The strip is then fed into a wire drawing die, which sequentially passes through dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm, and 2.0mm, drawing and reducing the diameter step by step to obtain the core powder wire. The diameter of the wear-resistant iron-based high-speed arc sprayed core powder wire obtained after drawing is 2mm.

[0033] The application of this wear-resistant iron-based high-speed arc-sprayed powder-core wire material, namely the method for preparing wear-resistant iron-based powder-core wire material coating, specifically includes the following steps:

[0034] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil stains from the substrate surface, and then iron sand is used to roughen the substrate surface; the substrate in step S1 is a Q235 steel substrate; the iron sand used for roughening is 16-18 mesh;

[0035] S2 Coating Preparation: A wear-resistant iron-based high-speed arc spraying technique is used to spray wear-resistant iron-based high-speed arc sprayed wire onto the treated substrate surface to obtain a wear-resistant iron-based wire coating. The spraying process parameters in step S2 are: air pressure: 0.6–0.7 MPa, spraying voltage: 28–40 V, spraying current: 180–240 A, spraying distance: 150–200 mm. An intermittent spraying method is used, repeating the spraying 6–10 times to obtain the wear-resistant iron-based wire coating. The porosity of the wear-resistant iron-based wire coating is ≤2.0%, and the Vickers hardness is 600 HV. 0.1 -800HV 0.1 .

[0036] Comparative Example: The wear-resistant iron-based high-speed arc sprayed powder core wire consists of a coating layer and a powder core. The powder core wire formula includes, by mass percentage, Mn: 10-15%, Cr: 8-15%, Ni: 3-5%, with the balance being Fe; the coating layer is 304 stainless steel strip; the preparation method of the high wear-resistant iron-based high-speed arc sprayed powder core wire is as follows: weigh Mn, Cr, Ni, and Fe powders according to the specified ratio; then mix the Mn, Cr, Ni, and Fe powders in a mixer to obtain a mixed powder; then... The powder core is obtained by sieving through a 100-mesh sieve. A 12mm wide and 0.3mm thick 304 stainless steel strip is tied into a U-shape, and the powder core is filled into the U-shaped stainless steel strip at a filling rate of 30% to 32%. The U-shaped 304 stainless steel strip is then closed to cover the powder core, and fed into a wire drawing die. The wire core is drawn and reduced in diameter sequentially through dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm, and 2.0mm to obtain the powder core wire. The diameter of the obtained powder core wire is 2mm. (This process of drawing and reducing diameter is repeated.)

[0037] The application of this wear-resistant iron-based high-speed arc-sprayed powder-core wire material, namely the method for preparing wear-resistant iron-based powder-core wire material coating, specifically includes the following steps:

[0038] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil from the substrate surface, followed by sandblasting with iron sand to roughen the surface. The purpose of pretreatment is to remove rust and create a uniformly rough surface to improve coating adhesion. The substrate in step S1 is a Q235 steel substrate, and the iron sand used for sandblasting is 16-18 mesh.

[0039] S2 Coating Preparation: A coating is prepared by spraying powder-cored wire onto a treated substrate using high-speed arc spraying technology. Spraying parameters are: air pressure: 0.6–0.7 MPa, spraying voltage: 27–35 V, spraying current: 200–240 A, spraying distance: 200–250 mm. An intermittent spraying method is used, repeating the spraying 6–10 times to obtain a coating of wear-resistant iron-based high-speed arc sprayed powder-cored wire. The thickness of the obtained wear-resistant iron-based high-speed arc sprayed powder-cored wire coating is 0.3–0.7 mm. The porosity of the wear-resistant iron-based high-speed arc sprayed powder-cored wire coating obtained in step S2 is ≤3.0%, and the Vickers hardness is 300 HV. 0.1 -400HV 0.1 . Specific Implementation Example 1:

[0041] The wear-resistant iron-based high-speed arc sprayed powder core wire consists of a cladding layer and a powder core. The powder core wire formula includes, by mass percentage: 13% Mn, 8% Cr, 5% Ni, 4% B, 5% Nb, 5% Al; balance Fe; the cladding layer is 304 stainless steel strip.

[0042] The preparation method of this wear-resistant iron-based high-speed arc sprayed powder core wire is as follows: First, weigh Mn, Cr, Ni, B, Nb, Al and Fe powders according to the ratio; mix the Mn, Cr, Ni, B, Nb, Al and Fe powders and mix them evenly in a mixer to obtain mixed powder; sieve the mixed powder through a 100-mesh sieve to obtain powder core powder; tie a 12mm wide and 0.3mm thick 304 stainless steel strip into a U-shape, and then fill the obtained powder core powder into the U-shaped stainless steel strip at a filling rate of 30%; then close the U-shaped stainless steel strip to cover the powder core powder, and then feed it into a wire drawing die, so that it passes through wire drawing dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm and 2.0mm in sequence, drawing and reducing the diameter one pass at a time to obtain powder core wire; the diameter of the obtained powder core wire is 2mm.

[0043] The wear-resistant iron-based high-speed arc sprayed powder-core wire is used to prepare a powder-core wire coating. The preparation method specifically includes the following steps:

[0044] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil from the substrate surface, followed by sandblasting with iron sand to roughen the surface. The purpose of pretreatment is to remove rust and create a uniformly rough surface to improve coating adhesion. The substrate in step S1 is a Q235 steel substrate, and the iron sand used for sandblasting is 16-18 mesh.

[0045] S2 Coating Preparation: A high-speed arc spraying technique was used to spray the powder-core wire onto the treated substrate to prepare the coating. The spraying process parameters were: air pressure: 0.65 MPa, spraying voltage: 27 V, spraying current: 200 A, and spraying distance: 200 mm. An intermittent spraying method was used, and the spraying was repeated 7 times to obtain a wear-resistant iron-based powder-core wire coating, namely the FeMnCrNiBNbAl coating, with a thickness of 0.5–0.6 mm.

[0046] Comparative Example 1:

[0047] The wear-resistant iron-based high-speed arc sprayed powder core wire consists of a coating layer and a powder core. The powder core wire formula includes, by mass percentage: 14% Mn, 10% Cr, 4% Ni, with the balance being Fe; the coating layer is 304 stainless steel strip.

[0048] The preparation method of this high wear-resistant iron-based high-speed arc sprayed powder-core wire is as follows: Mn, Cr, Ni, and Fe powders are weighed according to the specified ratio; the Mn, Cr, Ni, and Fe powders are then mixed and homogenized in a mixer to obtain a mixed powder; the mixed powder is then sieved through a 100-mesh sieve to obtain the powder core; a 12mm wide and 0.3mm thick 304 stainless steel strip is tied into a U-shape, and the powder core is filled into the U-shaped stainless steel strip at a 30% filling rate; the U-shaped 304 stainless steel strip is then closed to cover the powder core, and then fed into a wire drawing die, which sequentially draws and reduces the diameter of the wire through dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm, and 2.0mm to obtain the powder core wire; the diameter of the obtained powder core wire is 2mm. (This process of drawing and reducing the diameter of the wire is repeated.)

[0049] The application of this wear-resistant iron-based high-speed arc-sprayed powder-core wire material, namely the method for preparing wear-resistant iron-based powder-core wire material coating, specifically includes the following steps:

[0050] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil from the substrate surface, followed by sandblasting with iron sand to roughen the surface. The purpose of pretreatment is to remove rust and create a uniformly rough surface to improve coating adhesion. The substrate in step S1 is a Q235 steel substrate, and the iron sand used for sandblasting is 16-18 mesh.

[0051] S2 Coating Preparation: A coating was prepared by spraying powder-cored wire onto a treated substrate using high-speed arc spraying technology. The spraying parameters were: air pressure: 0.65 MPa, spraying voltage: 27 V, spraying current: 200 A, spraying distance: 200 mm. An intermittent spraying method was used, repeating the spraying process seven times to obtain a coating of wear-resistant iron-based high-speed arc sprayed powder-cored wire. The thickness of the obtained wear-resistant iron-based high-speed arc sprayed powder-cored wire coating was 0.3–0.7 mm. The porosity of the wear-resistant iron-based high-speed arc sprayed powder-cored wire coating obtained in step S2 was ≤3.0%, and the Vickers hardness was 300 HV. 0.1 -400HV 0.1 .

[0052] Specific Embodiment 2: The difference from Specific Embodiment 1 is the formula mass ratio of the powder core filament and the spraying parameters during application.

[0053] The wear-resistant iron-based high-speed arc sprayed powder core wire consists of a cladding layer and a powder core. The powder core wire formula includes, by mass percentage: 15% Mn, 9% Cr, 7% Ni, 6% B, 6% Nb, 7% Al, with the balance being Fe; the cladding layer is 304 stainless steel strip.

[0054] The preparation method of this wear-resistant iron-based high-speed arc sprayed powder core wire is as follows: First, weigh Mn, Cr, Ni, B, Nb, Al and Fe powders according to the ratio; mix the Mn, Cr, Ni, B, Nb, Al and Fe powders and mix them evenly in a mixer to obtain mixed powder; sieve the mixed powder through a 100-mesh sieve to obtain powder core powder; tie a 12mm wide and 0.3mm thick 304 stainless steel strip into a U-shape, and then fill the obtained powder core powder into the U-shaped stainless steel strip at a filling rate of 32%; then close the U-shaped stainless steel strip to cover the powder core powder, and then feed it into a wire drawing die, so that it passes through wire drawing dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm and 2.0mm in sequence, drawing and reducing the diameter one pass at a time to obtain powder core wire; the diameter of the obtained powder core wire is 2mm.

[0055] The wear-resistant iron-based high-speed arc sprayed powder-core wire is used to prepare a powder-core wire coating. The preparation method specifically includes the following steps:

[0056] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil from the substrate surface, followed by sandblasting with iron sand to roughen the surface. The purpose of pretreatment is to remove rust and create a uniformly rough surface to improve coating adhesion. The substrate in step S1 is a Q235 steel substrate, and the iron sand used for sandblasting is 16-18 mesh.

[0057] S2 Coating Preparation: A high-speed arc spraying technique was used to spray the powder-core wire onto the treated substrate to prepare the coating. The spraying process parameters were: air pressure: 0.65 MPa, spraying voltage: 36 V, spraying current: 220 A, and spraying distance: 200 mm. An intermittent spraying method was used, and the spraying was repeated 8 times to obtain a wear-resistant iron-based powder-core wire coating, namely the FeMnCrNiBNbAl coating, with a thickness of 0.5–0.6 mm.

[0058] Comparative Example 2:

[0059] The wear-resistant iron-based high-speed arc sprayed powder core wire consists of a coating layer and a powder core. The powder core wire formula includes, by mass percentage: 12% Mn, 9% Cr, 5% Ni, and the balance Fe; the coating layer is 304 stainless steel strip.

[0060] The preparation method of this high wear-resistant iron-based high-speed arc sprayed powder-core wire is as follows: Mn, Cr, Ni, and Fe powders are weighed according to the specified ratio; the Mn, Cr, Ni, and Fe powders are then mixed and homogenized in a mixer to obtain a mixed powder; the mixed powder is then sieved through a 100-mesh sieve to obtain the powder core; a 12mm wide and 0.3mm thick 304 stainless steel strip is tied into a U-shape, and the powder core is filled into the U-shaped stainless steel strip at a filling rate of 32%; the U-shaped 304 stainless steel strip is then closed to cover the powder core, and then fed into a wire drawing die, which sequentially draws and reduces the diameter of the wire through dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm, and 2.0mm to obtain the powder core wire; the diameter of the obtained powder core wire is 2mm. (This process of drawing and reducing the diameter of the wire is repeated.)

[0061] The application of this wear-resistant iron-based high-speed arc-sprayed powder-core wire material, namely the method for preparing wear-resistant iron-based powder-core wire material coating, specifically includes the following steps:

[0062] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil from the substrate surface, followed by sandblasting with iron sand to roughen the surface. The purpose of pretreatment is to remove rust and create a uniformly rough surface to improve coating adhesion. The substrate in step S1 is a Q235 steel substrate, and the iron sand used for sandblasting is 16-18 mesh.

[0063] S2 Coating Preparation: A coating was prepared by spraying powder-core wire onto a treated substrate using high-speed arc spraying technology. The spraying parameters were: air pressure: 0.65 MPa, spraying voltage: 36 V, spraying current: 220 A, spraying distance: 200 mm. An intermittent spraying method was used, repeating the process 8 times to obtain a wear-resistant iron-based high-speed arc sprayed powder-core wire coating. The thickness of the obtained wear-resistant iron-based high-speed arc sprayed powder-core wire coating was 0.3–0.7 mm. The porosity of the wear-resistant iron-based high-speed arc sprayed powder core coating obtained in step S2 was ≤3.0%, and the Vickers hardness was 300 HV. 0.1 -400HV 0.1 .

[0064] Specific embodiment 3: The difference from specific embodiment 1 is the formula mass ratio of the powder core filament and the spraying parameters during application.

[0065] The wear-resistant iron-based high-speed arc sprayed powder core wire consists of a cladding layer and a powder core. The powder core wire formula includes, by mass percentage: 16% Mn, 12% Cr, 8% Ni, 6% B, 7% Nb, 9% Al, with the balance being Fe; the cladding layer is 304 stainless steel strip.

[0066] The preparation method of this wear-resistant iron-based high-speed arc sprayed powder core wire is as follows: First, weigh Mn, Cr, Ni, B, Nb, Al and Fe powders according to the ratio; mix the Mn, Cr, Ni, B, Nb, Al and Fe powders and mix them evenly in a mixer to obtain mixed powder; sieve the mixed powder through a 100-mesh sieve to obtain powder core powder; tie a 12mm wide and 0.3mm thick 304 stainless steel strip into a U-shape, and then fill the obtained powder core powder into the U-shaped stainless steel strip at a filling rate of 30%; then close the U-shaped stainless steel strip to cover the powder core powder, and then feed it into a wire drawing die, so that it passes through wire drawing dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm and 2.0mm in sequence, drawing and reducing the diameter one pass at a time to obtain powder core wire; the diameter of the obtained powder core wire is 2mm.

[0067] The wear-resistant iron-based high-speed arc sprayed powder-core wire is used to prepare a powder-core wire coating. The preparation method specifically includes the following steps:

[0068] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil from the substrate surface, followed by sandblasting with iron sand to roughen the surface. The purpose of pretreatment is to remove rust and create a uniformly rough surface to improve coating adhesion. The substrate in step S1 is a Q235 steel substrate, and the iron sand used for sandblasting is 16-18 mesh.

[0069] S2 Coating Preparation: A high-speed arc spraying technique was used to spray the powder-core wire onto the treated substrate to prepare the coating. The spraying process parameters were: air pressure: 0.7 MPa, spraying voltage: 36 V, spraying current: 240 A, and spraying distance: 150 mm. An intermittent spraying method was used, and the spraying was repeated 10 times to obtain a wear-resistant iron-based powder-core wire coating, namely the FeMnCrNiBNbAl coating, with a thickness of 0.5–0.6 mm.

[0070] Comparative Example 3:

[0071] The wear-resistant iron-based high-speed arc sprayed powder core wire consists of a coating layer and a powder core. The powder core wire formula includes, by mass percentage: 14% Mn, 9% Cr, 5% Ni, with the balance being Fe; the coating layer is 304 stainless steel strip.

[0072] The preparation method of this high wear-resistant iron-based high-speed arc sprayed powder-core wire is as follows: Mn, Cr, Ni, and Fe powders are weighed according to the specified ratio; the Mn, Cr, Ni, and Fe powders are then mixed and homogenized in a mixer to obtain a mixed powder; the mixed powder is then sieved through a 100-mesh sieve to obtain the powder core; a 12mm wide and 0.3mm thick 304 stainless steel strip is tied into a U-shape, and the powder core is filled into the U-shaped stainless steel strip at a 30% filling rate; the U-shaped 304 stainless steel strip is then closed to cover the powder core, and then fed into a wire drawing die, which sequentially draws and reduces the diameter of the wire through dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm, and 2.0mm to obtain the powder core wire; the diameter of the obtained powder core wire is 2mm. (This process of drawing and reducing the diameter of the wire is repeated.)

[0073] The application of this wear-resistant iron-based high-speed arc-sprayed powder-core wire material, namely the method for preparing wear-resistant iron-based powder-core wire material coating, specifically includes the following steps:

[0074] S1 Substrate Surface Pretreatment: Anhydrous ethanol is used to remove stains and oil from the substrate surface, followed by sandblasting with iron sand to roughen the surface. The purpose of pretreatment is to remove rust and create a uniformly rough surface to improve coating adhesion. The substrate in step S1 is a Q235 steel substrate, and the iron sand used for sandblasting is 16-18 mesh.

[0075] S2 Coating Preparation: A coating was prepared by spraying powder-cored wire onto a treated substrate using high-speed arc spraying technology. The spraying parameters were: air pressure: 0.7 MPa, spraying voltage: 36 V, spraying current: 240 A, spraying distance: 150 mm. An intermittent spraying method was used, repeating the spraying process 10 times to obtain a wear-resistant iron-based high-speed arc sprayed powder-cored wire coating. The thickness of the obtained wear-resistant iron-based high-speed arc sprayed powder-cored wire coating was 0.5–0.6 mm. The porosity of the wear-resistant iron-based high-speed arc sprayed powder-cored wire coating obtained in step S2 was ≤3.0%, and the Vickers hardness was 300 HV. 0.1 -400HV 0.1 .

[0076] The specific embodiments 1 to 3 and the comparative embodiments 1 to 3 were characterized in terms of composition, structure and performance.

[0077] (1) Composition and structure analysis:

[0078] 1) Scanning electron microscopy and EDS analysis: The coatings (FeMnCrNiBNbAl coatings) of the wear-resistant iron-based high-speed arc sprayed powder core wires obtained in specific embodiments 1 to 3 of the present invention were analyzed by scanning electron microscopy. Figure 1The SEM morphology of the coating (FeMnCrNiBNbAl coating) of the wear-resistant iron-based high-speed arc-sprayed powder-core wire in Specific Embodiment 1 is shown below. Figure 1 As can be seen, the surface of the coating (FeMnCrNiBNbAl coating) of the wear-resistant iron-based high-speed arc sprayed powder core wire exhibits a smooth area after the molten droplets have spread, as well as some small pores after condensation and shrinkage. Figure 2 The cross-sectional morphology of the wear-resistant iron-based high-speed arc-sprayed powder-core wire (FeMnCrNiBNbAl coating) in Specific Embodiment 1 shows a layered structure. Figure 2 As can be seen, the coating has a uniform and dense structure. Gray-scale analysis shows the coating porosity to be 0.84%, and the coating of this wear-resistant iron-based high-speed arc-sprayed powder-core wire exhibits strong mechanical bonding with the substrate, demonstrating good adhesion. Figure 3 The image shown is a metallographic diagram of specific embodiment 1. Figure 3 As can be seen, the coating has uniform and fine grains, and contains a small amount of oxides and pores. The banded structure, formed by the alternating layering of ferrite and pearlite along the rolling deformation direction, causes anisotropy in the mechanical properties of the FeMnCrNiBNbAl coating, i.e., high strength and good toughness along the longitudinal direction of the banded structure. Figure 4 The figure shown is an EDS analysis diagram of specific embodiment 1. From the EDS elemental distribution scanning results of the coating (FeMnCrNiBNbAl coating), it can be seen that the coating of the prepared wear-resistant iron-based high-speed arc sprayed powder core wire is mainly composed of seven main elements: Fe, Mn, Cr, Ni, B, Nb, and Al. From the distribution diagram, it can be seen that the detection amounts of Fe, Mn, Cr, Ni, Nb, and Al are all very large. Among them, the B element is difficult to detect due to its small atomic number, so the detection results show less.

[0079] 2) XRD characterization analysis: Figure 5 The XRD pattern of the coating of the wear-resistant iron-based high-speed arc-sprayed powder-core wire in Specific Embodiment 1 is shown below. Figure 5 Crystal peaks can be observed at 45°, 51°, 65°, and 80°. The wear-resistant iron-based high-speed arc-sprayed powder core wire coating mainly consists of α-Fe phase, Fe-Cr phase, Fe-Ni phase, Ni-Cr-Fe phase, and (Fe-Ni) solid solution phase.

[0080] (2) Performance testing: Performance testing included porosity, hardness, and wear rate. The coatings prepared in specific examples 1-3 and comparative examples 1-3 were used to calculate the coating porosity using the ImageJ software grayscale test method. Ten regions were selected for calculation in each specific example, and the average value of the results was taken. The coating hardness was measured using a Duramin-40A1 microhardness tester with a load of 100g and a loading time of 15s. The tribological properties of the coating were tested using a CFT-I material surface performance comprehensive tester. The grinding part was a Si3N4 ball with a diameter of 4mm, the test load was 6N, the test reciprocating speed was 900t / min, the test time was 30min, and the scratch length was 2mm. The scratch was analyzed using an OLS4100 laser confocal microscopy at magnifications of 10X, 16X, and 20X, and the coating wear rate was calculated.

[0081] Table 1 shows the performance test data of the coatings (FeMnCrNiBNbAl coating) of the wear-resistant iron-based high-speed arc-sprayed powder-core wires in Examples 1-3 and the coatings (FeMnCrNi coating) of the iron-based high-speed arc-sprayed powder-core wires in Comparative Examples 1-3. As can be seen from the table, under the same high-speed spraying process parameters, the FeMnCrNiBNbAl coating has lower porosity, lower wear rate, and higher hardness. Generally, the lower the porosity and wear rate, the better the wear resistance.

[0082] Table 1 shows the test results of porosity, hardness, and wear rate for all embodiments.

[0083]

[0084]

[0085] Reasonable process parameters are fundamental to ensuring good coating performance. Spraying voltage, spraying current, spraying distance, and spraying air pressure affect the temperature, size distribution, flight speed, and oxidation rate of molten particles during spraying, leading to variations in coating density, uniformity, and stress distribution. This indirectly affects coating porosity, hardness, and wear resistance. The performance test results show that the powder-core wire prepared according to the formulation of this invention, when used in the preparation of wear-resistant iron-based powder-core wire coatings, can form a continuous and dense arc-sprayed alloy coating on a Q235 steel substrate. This coating exhibits advantages such as low porosity, high hardness, and good wear resistance, and can be widely applied in surface wear-resistant processes for shaft components.

[0086] For those skilled in the art, the specific embodiments are merely illustrative descriptions of the present invention. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A wear-resistant iron-based high-speed arc-sprayed powder-core wire, characterized in that, This wear-resistant iron-based high-speed arc sprayed powder core wire consists of a coating layer and a powder core. The powder core formula includes, by mass percentage: Mn: 13~16%; Cr: 8~12%; Ni: 5~8%; B: 4~6%; Nb: 5~7%; Al: 5-9%; with the balance being Fe.

2. The wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 1, characterized in that, The preparation method of the wear-resistant iron-based high-speed arc sprayed powder core wire is as follows: the uniformly mixed powder core is filled into the coating layer, and the coating layer is closed to cover the powder core, and then the wear-resistant iron-based high-speed arc sprayed powder core wire is obtained by drawing through a drawing die.

3. The wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 2, characterized in that, During the preparation process, the core powder is obtained by mixing Mn powder, Cr powder, Ni powder, B powder, Nb powder, Al powder and Fe powder weighed according to the formula ratio using a mixer, and then sieving the mixture to obtain a uniformly mixed core powder.

4. The wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 2, characterized in that, The coating layer is made of 304 stainless steel strip. Before filling the core powder into the coating layer, the 304 stainless steel strip is first tied into a U-shape. After filling the core powder, the U-shaped stainless steel strip is closed, so that the U-shaped stainless steel strip covers the core powder. Then it is fed into the wire drawing die and drawn and reduced in diameter step by step to obtain the core wire.

5. The wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 4, characterized in that, When the coated stainless steel strip is fed into the drawing die, it passes through the drawing dies with diameters of 3.0mm, 2.6mm, 2.4mm, 2.2mm and 2.0mm in sequence, and is drawn and reduced in diameter one by one to obtain powder core wire.

6. The wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 4, characterized in that, A 12mm wide and 0.3mm thick 304 stainless steel strip is tied into a U-shape, and then the evenly mixed core powder is filled into the U-shaped stainless steel strip at a filling rate of 30%~32%.

7. The wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 6, characterized in that, The diameter of the wear-resistant iron-based high-speed arc sprayed powder core wire obtained after drawing is 2mm.

8. The application of the wear-resistant iron-based high-speed arc-sprayed powder-core wire according to any one of claims 1-7, characterized in that, A wear-resistant iron-based powder-core wire coating was prepared using a wear-resistant iron-based high-speed arc spraying powder-core wire. The preparation method specifically includes the following steps: S1 substrate surface pretreatment: Anhydrous ethanol is used to remove stains and oil stains from the substrate surface, and then iron sand is used to roughen the substrate surface. S2 coating preparation: Wear-resistant iron-based high-speed arc spraying powder core wire is sprayed onto the treated substrate surface using high-speed arc spraying technology to obtain a wear-resistant iron-based powder core wire coating.

9. The application of the wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 8, characterized in that, The substrate in step S1 is a Q235 steel substrate; the iron sand used for sandblasting roughening is 16-18 mesh.

10. The application of the wear-resistant iron-based high-speed arc-sprayed powder-core wire according to claim 8, characterized in that, The spraying process parameters in step S2 are as follows: air pressure: 0.6~0.7MPa, spraying voltage: 28~40V, spraying current: 180~240A, spraying distance: 150~200mm; an intermittent spraying method is used, and the spraying is repeated 6~10 times to obtain a wear-resistant iron-based powder core wire coating. The porosity of the wear-resistant iron-based powder core wire coating is ≤2.0%, and the Vickers hardness is 600HV. 0.1 -800HV 0.1 .

Images