A method for manufacturing a metal composite ceramic wear-resistant insert and an embedding method

Abstract

This invention relates to a method for manufacturing and installing wear-resistant inserts, specifically a method for manufacturing a metal-ceramic wear-resistant insert with excellent wear resistance using a closed tube and hot pressing with an active metal, and a method for installing the wear-resistant insert. This addresses the shortcomings of equipment used in the production of granular materials and / or powder materials, which employs wear-resistant components embedded with alumina ceramic particles. These components suffer from cumbersome manufacturing processes, high costs, insufficient wear resistance, and the inability to manufacture small, thin, and large-area workpieces. The manufacturing and installation method of this metal-ceramic wear-resistant insert involves filling a mixed material into a closed tube, pressing and shrinking the tube under high temperature and vacuum to ensure the mixed material within the tube is fully compacted, and then using an active material composite metal to form the wear-resistant insert under high temperature and high pressure.

Description

Technical Field

[0001] This invention relates to a method for manufacturing and installing wear-resistant inserts, specifically to a method for manufacturing a metal composite ceramic wear-resistant insert with excellent wear resistance using a closed tube and active metal hot pressing, and a method for installing the wear-resistant insert. Background Technology

[0002] Granular and powder materials have always played an important role in the development of various industries, especially in industries such as cement production, mining, thermal power generation, building sand making, metallurgy, and chemical industry. Most of the equipment in these industries produces both granular and powder materials.

[0003] There are two main types of equipment used for producing powder materials: one is the roller mill, which works by pressing powder onto a liner using rollers. Roller mills mainly include vertical mills and Raymond mills. The other type is the ball mill, which works by placing a large number of round balls and the raw material to be powdered inside a horizontally positioned drum. As the drum rotates, the round balls rise with it, and upon reaching a high point, they are thrown down, striking the material below and thus producing powder.

[0004] The main types of equipment used for producing granular materials include: extrusion crushing equipment (such as double roll crushers, cone crushers, jaw crushers, gyratory crushers, etc.); and impact crushing equipment (such as hammer crushers, impact crushers, compound crushers, etc.).

[0005] Since most materials subjected to crushing, granulation, and grinding have a hardness greater than carbon steel, crushing and grinding equipment wears out quickly, resulting in a very short service life. To address this issue, this field employs the method of adding high-hardness alloy steel inserts to a carbon steel substrate. This method not only effectively extends the service life of the equipment but also significantly improves its output. This is because the workpiece with the insert greatly reduces slippage of the crushed, granulated, and ground materials on the steel substrate during operation, significantly reducing ineffective energy consumption and increasing the equipment's output.

[0006] However, the wear resistance of workpieces with high-hardness alloy steel inserts still cannot meet the needs of industrial production. Those skilled in the art have attempted to incorporate high-hardness structural ceramics into steel-based workpieces to improve various performance characteristics. Currently, the practically applicable manufacturing method involves: first, sintering larger alumina ceramic particles using the molybdenum-manganese method, followed by electroplating to metallize the surface of the alumina ceramic particles; then, placing the alumina ceramic particles into predetermined positions within a casting mold, and finally injecting liquid metal into the mold to create a wear-resistant part inlaid with alumina ceramic particles. While this method produces wear-resistant parts with excellent performance, it suffers from cumbersome processes and high costs. Furthermore, this method can only use large alumina ceramic particles and cannot utilize multi-stage ceramic particle combinations to further improve wear resistance because the liquid metal cannot completely fill the spaces between the ceramic particles. Additionally, this method cannot produce relatively small, thin, and large-area workpieces. Summary of the Invention

[0007] The purpose of this invention is to address the shortcomings of equipment for producing granular materials and / or powder materials that uses wear-resistant parts embedded with alumina ceramic particles, which have complicated manufacturing processes, high prices, insufficient wear resistance, and cannot produce relatively small and thin workpieces with large areas. Therefore, this invention provides a method for manufacturing and embedding a metal composite ceramic wear-resistant insert.

[0008] To address the shortcomings of the existing technology, the present invention provides the following technical solution:

[0009] A method for manufacturing a metal-ceramic wear-resistant insert, characterized by the following steps:

[0010] Step 1: Prepare the base tube for making the corresponding closed shrink tube according to the size of the wear-resistant insert;

[0011] Step 2: Prepare the mixing materials;

[0012] The mixed material comprises structural ceramic particles, metal particles, and active solder in a volume ratio of 3.5–5.5:3.5–5.5:1–2.5.

[0013] The particle size of the structural ceramic particles is 0.1–3 mm;

[0014] The particle size of the metal particles is 0.3–2 mm;

[0015] The active solder includes an active metal and auxiliary materials, wherein the auxiliary materials include one or a combination of copper, copper alloys, nickel, chromium, and boron.

[0016] Step 3: After cleaning the inner wall of the original tube, first seal one end of the original tube, mix the mixed material from step 2 evenly and fill it into the original tube, then vibrate and compact it. Then seal the other end of the original tube and weld the vacuum tube interface onto the original tube to obtain a sealed shrink tube. Vacuum the sealed shrink tube, heat and extrude it to make the preset shape of the wear-resistant insert. Finally, cut and process the sealed shrink tube to obtain the wear-resistant insert.

[0017] Further, in step 2, the structural ceramic particles are one or a combination of alumina, silicon carbide, titanium carbide reinforced alumina, silicon carbide reinforced alumina, boron carbide reinforced alumina, and titanium carbide reinforced silicon carbide particles.

[0018] The metal particles are one or a combination of carbon steel alloy, stainless steel, manganese steel alloy, nickel steel alloy, and chromium steel alloy particles.

[0019] The active metal includes one or a combination of titanium, titanium alloys, and titanium hydride.

[0020] Furthermore, step 3 specifically includes:

[0021] Step 3.1: After cleaning the inner wall of the original tube, first seal one end of the original tube, mix the mixed material from step 2 evenly and fill it into the original tube, then vibrate and compact it. Then seal the other end of the original tube and weld the air extraction pipe interface at this end to obtain a sealed shrink tube.

[0022] Step 3.2: Place the sealed tube into the low-temperature heating device. First, extract the gas from the sealed tube through the evacuation pipe interface. Then, turn on the low-temperature heating device to heat the sealed tube to 250℃~650℃. At the same time, continue to extract the gas from the sealed tube through the evacuation pipe interface. When the vacuum degree in the sealed tube is higher than 3~30KPa, close the evacuation pipe interface.

[0023] Step 3.3: Place the sealed shrink tube into a medium-temperature heating device, heat it to the set temperature, and keep it at that temperature for more than 5 minutes to make the temperature inside and outside the sealed shrink tube uniform; the set temperature is 10℃~100℃ lower than the melting point of the active solder.

[0024] Step 3.4: Place the closed tube into the densification extrusion tube compression unit. The tube is squeezed and shrunken step by step by different tube shrinking heads in the densification extrusion tube compression unit, so that the size of the closed tube gradually decreases and the mixed material inside the closed tube gradually becomes denser, reaching the preset density.

[0025] Step 3.5: Place the sealed shrink tube into a high-temperature heating device and heat it to 1050℃~1120℃. Hold it at that temperature for more than 30 minutes to allow the molten active solder to react with the structural ceramic particles.

[0026] Step 3.6: Place the closed shrink tube into the forming, extrusion and stretching tube unit. As the closed shrink tube gradually cools down, it is simultaneously pressed and shaped by the forming, extrusion and stretching tube unit to form the preset shape of the wear-resistant insert.

[0027] Step 3.7: Cut and process the closed tube obtained in step 3.6 to obtain the wear-resistant insert.

[0028] Furthermore, in step 1, the radial dimension of the inner wall of the original tube is 1.15 to 2 times the corresponding dimension of the wear-resistant insert, and the wall thickness of the original tube is 1 mm to 5 mm.

[0029] Furthermore, in step 2, the mixed material also includes a liquid, the mass of which is 0.05% to 3% of the mass of the mixed material, and the liquid includes ethyl acetate, anhydrous ethanol, and distilled water.

[0030] Further, in step 3.1, the first step is to seal one end of the closed shrink tube, and the second step is to seal the other end of the closed shrink tube by local induction heating or by welding.

[0031] Furthermore, the medium-temperature heating device mentioned in step 3.3 and the high-temperature heating device mentioned in step 3.5 are both devices that can simultaneously and orderly insert and output multiple closed constricted tubes.

[0032] Meanwhile, the present invention also provides a method for installing a metal composite ceramic wear-resistant insert, which is characterized by including the following steps:

[0033] Step 1: Fabricate at least one wear-resistant insert according to the above-described method for manufacturing metal-ceramic wear-resistant inserts;

[0034] Step 2: The wear-resistant inserts obtained in Step 1 are directly embedded or encapsulated in liquid metal and then embedded onto the workpiece to form a semi-finished product. The semi-finished product is then machined and heat-treated to form a finished product, thus completing the embedding process.

[0035] Further, in step 2, the direct embedding specifically refers to:

[0036] Drill holes in the workpiece and then insert wear-resistant inserts into the holes by means of interference fit after heating, welding, or bonding.

[0037] Further, in step 2, the liquid metal encapsulation and embedding specifically involves:

[0038] Weld the multiple wear-resistant inserts obtained in step 1 together with the steel connecting frame, place the steel connecting frame with the multiple wear-resistant inserts into the casting mold, and then inject liquid metal into the casting mold.

[0039] Compared with the prior art, the beneficial effects of the present invention are:

[0040] (1) This invention provides a method for manufacturing a metal composite ceramic wear-resistant insert, used to produce wear-resistant inserts with excellent wear resistance, superior mechanical properties, and low cost. The wear-resistant insert is one of the following: inserting a toothed pin on a cutting tooth, inserting a roller pin and roller strip on a pressure roller, inserting a tooth core on a screw conveyor, inserting a grinding roller pin and roller strip on a grinding roller, or inserting a liner pin and liner strip on a liner plate. The method involves filling a mixed material into a closed shrink tube, pressing and shrinking the closed shrink tube under high temperature and vacuum to ensure the mixed material inside the closed shrink tube is fully compacted, and then using an active material composite metal to make the wear-resistant insert under high temperature and high pressure. This invention draws on the advantages of existing technologies and overcomes their limitations. Due to the use of a closed shrink tube, liquid metal with active metal is diffused into structural ceramic particles under high temperature and high pressure. Wherein:

[0041] A. The present invention uses a high-pressure diffusion process, changing solid high-pressure diffusion to liquid high-pressure diffusion; thus, it is no longer limited by the melting point of the diffusion metal, increasing the diffusion temperature can appropriately reduce the diffusion pressure, and at the same time greatly shorten the diffusion time and improve the production capacity.

[0042] B. The present invention uses an active metal process, in which active metal is added to the high-pressure diffusion liquid metal, which improves the activity of the liquid metal. This not only improves the wettability of the liquid metal to the structural ceramic particles, accelerates the diffusion rate, and reduces the diffusion pressure, but also, by appropriately adjusting the amount of active metal added, the melting point of the active solder and the amount of reactants produced can be effectively adjusted, and the thickness of the reactants between the metal and the ceramic can be effectively controlled. This not only optimizes the connection strength between the two, but also allows the wear-resistant insert to be installed at room temperature or in the liquid metal.

[0043] C. The wear-resistant insert produced by this invention consists of metal encapsulating structural ceramic particles. Because each structural ceramic particle has a relatively small surface area, the internal stress between the metal and ceramic is very small. Therefore, the difference in thermal expansion between the metal and ceramic can be disregarded, and a trace amount or no flexible metal can be added to the active solder. However, when the average thermal expansion coefficient of the mixed particles differs significantly from that of the closed constriction tube and the cast inlaid liquid metal material, the technical performance of the wear-resistant insert will be greatly reduced. This invention, by rationally blending structural ceramic particles of different materials and metal particles with different thermal expansion coefficients, and by rationally adjusting the amount and material of the active solder, can produce wear-resistant inserts with an average thermal expansion coefficient similar to that of the cast inlaid metal, ensuring that the impact on the intrinsic quality of the wear-resistant insert is minimized.

[0044] D. The metal particles used in this invention are connected by active solder within the wear-resistant insert to form a three-dimensional network structure. Because there are many types of metal particles to choose from, the requirements for manufacturing wear-resistant inserts can be fully met. After heat treatment, the manufactured wear-resistant inserts can achieve excellent performance. Therefore, the wear-resistant inserts manufactured in this invention can be used to be embedded in various crushing equipment, such as cone crushers, impact crushers, jaw crushers, double roll crushers, gyratory crushers, hammer crushers, impact crushers, and compound crushers.

[0045] (2) The present invention discloses a method for manufacturing a metal composite ceramic wear-resistant insert, which involves extruding and compressing the tube when the active solder is close to melting. At this time, the active solder is still coated on the surface of the structural ceramic particles and the metal particles. At this time, the metal particles have softened. The tube is then extruded and compressed to deform the metal particles according to the shape of the adjacent structural ceramic particles, which greatly increases the contact area between the metal particles and the structural ceramic particles and evenly sandwiches the active solder between them. This prepares the material for subsequent high-temperature composite. At the same time, it avoids the problem of uneven distribution of active solder caused by surface tension and gravity after the active solder melts. This improves the quality of the wear-resistant insert product.

[0046] (3) The present invention provides a method for manufacturing a metal composite ceramic wear-resistant insert. The closed tube shrinkage and manufacturing process greatly simplify the manufacturing process and at the same time greatly improve the quality of the product: First, the use of closed tube shrinkage improves the uniformity of the wear-resistant insert product; Second, the present invention uses electromagnetic induction local heating in many places in the manufacturing process, so that the entire manufacturing process can be effectively controlled; This prepares for the next step of fully automatic intelligent control production.

[0047] (4) The method for manufacturing a metal composite ceramic wear-resistant insert of the present invention uses active solder to composite and form under high temperature and high pressure; however, if the structural ceramic particles are surface metallized structural ceramic particles made by molybdenum-manganese method or chemical method combined with electroplating, the present invention can still be used.

[0048] (5) In the manufacturing method of the metal composite ceramic wear-resistant insert of the present invention, the vacuum environment provided by the closed shrink tube avoids the reaction of structural ceramic particles, metal particles, and active solder with gas at high temperature, thereby avoiding the reduction of the composite connection strength of active solder on the surface of structural ceramic particles due to reaction products, ensuring that active solder can penetrate, diffuse and react on the surface of structural ceramic particles, so that active solder can wet the surface of structural ceramic particles, and at the same time eliminates the possibility of active solder blistering, cracking, peeling and falling off on the surface of structural ceramic particles, avoiding the decrease of the connection strength of active solder on the surface of structural ceramic particle material; thereby enabling active solder to be tightly connected with the surface of structural ceramic particles, and obtaining a wear-resistant insert with excellent performance.

[0049] (6) In the manufacturing method of the metal composite ceramic wear-resistant insert of the present invention, the materials used can be recycled and reused, saving material costs, reducing energy consumption and environmental pollution.

[0050] (7) The present invention provides a method for installing a metal composite ceramic wear-resistant insert. The wear-resistant insert is manufactured using the above method. The installation is either direct installation or metal molten liquid encapsulation installation. The present invention has the advantages of simple process steps and good wear resistance of finished product. It can be used to install wear-resistant roller nails and wear-resistant inserts on pressure rollers, to install wear-resistant roller nails and wear-resistant inserts on grinding rollers, and to install wear-resistant liner nails and wear-resistant liner strips on liners. Attached Figure Description

[0051] Figure 1 This is a flowchart illustrating Embodiments 1 to 3 of the method for manufacturing a metal composite ceramic wear-resistant insert according to the present invention;

[0052] Figure 2 This is a schematic diagram of the closed constricted tube obtained in step 3.1 of Embodiment 1 of the present invention;

[0053] Figure 3 This is a schematic diagram of the closed constricted tube obtained in step 3.6 of Embodiment 1 of the present invention;

[0054] Figure 4 This is a partially enlarged schematic diagram of the mixed material before step 3.4 in Embodiment 1 of the present invention, when it is not compressed inside the closed constriction tube;

[0055] Figure 5 This is a partially enlarged schematic diagram of the mixed material after step 3.4 in Embodiment 1 of the present invention, after being pressed inside a closed constriction tube;

[0056] Figure 6 This is a schematic cross-sectional view of a cylindrical wear-resistant insert in an embodiment of the manufacturing method of a metal composite ceramic wear-resistant insert of the present invention.

[0057] Figure 7 This is a schematic cross-sectional view of a rectangular prism in Embodiment 1 of the method for manufacturing a metal composite ceramic wear-resistant insert according to the present invention.

[0058] Figure 8 This is a schematic cross-sectional view of a multi-faceted prism in an embodiment of the manufacturing method of a metal composite ceramic wear-resistant insert of the present invention.

[0059] Figure 9 This is a schematic diagram of the structure of a wavy strip in Embodiment 1 of the manufacturing method of a metal composite ceramic wear-resistant insert of the present invention;

[0060] Figure 10This is a schematic diagram of the structure of a corrugated strip in Embodiment 1 of the method for manufacturing a metal composite ceramic wear-resistant insert according to the present invention. Figure 1 ;

[0061] Figure 11 This is a schematic diagram of the structure of a corrugated strip in Embodiment 1 of the method for manufacturing a metal composite ceramic wear-resistant insert according to the present invention. Figure 2 ;

[0062] Figure 12 This is a schematic diagram of the structure of step 2 in an embodiment of the method for installing a metal composite ceramic wear-resistant insert according to the present invention, in which the wear-resistant insert is placed into the central hole of the cutting tooth steel sleeve.

[0063] Figure 13 This is a schematic diagram of the welding of multiple wear-resistant inserts to a steel connecting frame in step 2 of an embodiment of the method for installing a metal composite ceramic wear-resistant insert according to the present invention.

[0064] Figure 14 This is a schematic diagram of the welding of multiple wear-resistant inserts to a steel connecting frame in step 2 of embodiment 3 of the method for installing a metal composite ceramic wear-resistant insert according to the present invention.

[0065] The annotations in the attached figures are explained as follows:

[0066] 8-Closed shrink tube; 9-Mixed material; 10-Evacuation pipe interface; 11-Wear-resistant insert; 20-Structural ceramic particles; 21-Metal particles; 22-Active solder; 30-Cutting tooth steel sleeve; 31-Steel connecting frame. Detailed Implementation

[0067] The present invention will be further described below with reference to the accompanying drawings and exemplary embodiments.

[0068] This invention discloses a method for manufacturing a metal composite ceramic wear-resistant insert, comprising the following steps:

[0069] Step 1: Prepare the base tube for making the corresponding closed shrink tube according to the size of the wear-resistant insert;

[0070] Step 2: Prepare the mixing materials;

[0071] The mixed material includes structural ceramic particles, metal particles, active solder, and a small amount of liquid in a volume ratio of 3.5-5.5:3.5-5.5:1-2.5. The liquid includes substances that can be completely evaporated and decomposed during the heating process, leaving no residue that has an adverse effect on the wear-resistant insert.

[0072] The particle size of the structural ceramic particles is 0.1–3 mm;

[0073] The particle size of the metal particles is 0.3–2 mm;

[0074] The active solder includes an active metal and auxiliary materials, wherein the auxiliary materials include one or a combination of copper, copper alloys, nickel, chromium, and boron.

[0075] Step 3: After cleaning the inner wall of the original tube, first seal one end of the original tube, mix the mixed material from step 2 evenly and fill it into the original tube, then vibrate and compact it. Then seal the other end of the original tube and weld the vacuum tube interface onto the original tube to obtain a sealed shrink tube. Vacuum the sealed shrink tube, heat and extrude it to make the preset shape of the wear-resistant insert. Finally, cut and process the sealed shrink tube to obtain the wear-resistant insert.

[0076] The following specific embodiments illustrate the manufacturing method of a metal-ceramic wear-resistant insert according to the present invention:

[0077] Example 1

[0078] Reference Figures 1 to 5 A method for manufacturing a metal-ceramic wear-resistant insert includes the following steps:

[0079] Step 1: Prepare the original tube for the closed shrink tube 8 according to the wear-resistant insert 11;

[0080] In this embodiment, the wear-resistant insert 11 has a diameter of 25mm, and the original tube 8 is a Q235 carbon steel original tube with a length of 3 meters, an inner diameter of 35mm, and a wall thickness of 1.2mm.

[0081] Step 2: Prepare the mixed ingredients 9;

[0082] The mixed material 9 consists of structural ceramic particles 20, metal particles 21, and active solder 22 in a volume ratio of 3.5:5.3 to 5.5:1 to 1.2, and a liquid with a mass ratio of 3%, which is composed of ethyl acetate, anhydrous ethanol, and distilled water.

[0083] The structural ceramic particles 20 are made of alumina ceramic particles with a particle size of 0.5 to 0.8 mm.

[0084] Metal particles 21 are made of carbon steel alloy with a particle size of 0.5–0.8 mm;

[0085] Active solder 22 is made of titanium-copper mixed powder;

[0086] Step 3: Fabricate wear-resistant insert 11;

[0087] Step 3.1: After cleaning the inner wall of the original tube, first seal one end of the original tube. Then, mix the mixture 9 from step 2 thoroughly and fill the original tube completely, vibrating and compacting it. Next, seal the other end of the original tube and weld the extraction pipe interface 10 to that end to obtain the sealed constricted tube 8. Figure 2 As shown;

[0088] The sealing method involves local induction heating followed by tube shrinkage sealing.

[0089] Step 3.2: Place the sealed tube 8 into the low-temperature heating device. First, extract the gas inside the sealed tube 8 through the extraction pipe interface 10. When the vacuum degree inside the sealed tube 8 is close to 3-30 kPa, turn on the low-temperature heating device to heat the sealed tube 8 to 500°C. At the same time, continue to extract the gas inside the sealed tube 8 (including the gas that evaporates or decomposes at high temperature) through the extraction pipe interface 10. When the vacuum degree inside the sealed tube 8 is higher than 3-30 kPa, close the extraction pipe interface 10.

[0090] Step 3.3: Place the sealed shrink tube 8 into a medium-temperature heating device and heat it to the set temperature of 900℃~950℃. Hold it at this temperature for 5 minutes to make the temperature inside and outside the sealed shrink tube 8 uniform. The set temperature is 10℃~100℃ lower than the melting point of the active solder 22.

[0091] Step 3.4: Place the closed-loop tube 8 into the densification extrusion and compression unit. The tube is progressively compressed by tube-shrinking heads of different diameters within the unit, gradually reducing the diameter of the closed-loop tube 8 and densifying the mixed material 9 inside, achieving the preset required density. Figure 4 , Figure 5 As shown;

[0092] Step 3.5: Place the closed shrink tube 8 into a high-temperature heating device and heat it to 1100℃~1120℃. Keep it at this temperature for 30 minutes to allow the molten active solder 22 to react with the structural ceramic particles 20.

[0093] Step 3.6: Place the closed-circuit tube 8 into the forming, extrusion, and stretching tube compression unit. As the closed-circuit tube 8 gradually cools, it is simultaneously pressed and shaped by the forming, extrusion, and stretching tube compression unit. After the liquid metal inside the closed-circuit tube 8 solidifies, an induction heating device is used to locally heat the closed-circuit tube 8, while a rotary extrusion device is used to squeeze the closed-circuit tube 8, causing it to locally shrink and form the wear-resistant insert 11 into the preset shape, such as... Figure 3 As shown;

[0094] Step 3.7: Cut and process the closed tube 8 obtained in step 3.6 to obtain the wear-resistant insert 11.

[0095] The medium-temperature heating device in step 3.3 and the high-temperature heating device in step 3.5 are both devices that can simultaneously and orderly insert and output multiple closed constricted tubes 8.

[0096] In other embodiments, the wear-resistant insert 11 can be a cylinder, a rectangular prism, or a polygonal prism, as shown below. Figure 6 , Figure 7 , Figure 8As shown, its end face can be a plane, a spherical surface, a conical surface, or a polygonal pyramid. The wear-resistant insert 11 can also be a straight or arc-shaped strip with a square or rectangular cross-section; and a wavy or corrugated strip with a square or rectangular cross-section, such as... Figure 9 , Figure 10 , Figure 11 As shown.

[0097] Example 2

[0098] Reference Figure 1 A method for manufacturing a metal-ceramic wear-resistant insert includes the following steps:

[0099] Step 1: Prepare the original tube for the closed shrink tube 8 according to the wear-resistant insert 11;

[0100] The inner wall of the closed constriction tube 8 is cleaned, and the closed constriction tube 8 is provided with an air extraction pipe interface 10, such as... Figure 2 As shown;

[0101] In this embodiment, the wear-resistant insert 11 has a rectangular cross-section that is 30mm wide and 45mm long; the original tube is a Q235 carbon steel original tube that is 3 meters long, 50mm inner diameter, and 5mm wall thickness; in other embodiments, the wall thickness of the original tube can be 1mm to 5mm.

[0102] Step 2: Prepare the mixed ingredients 9;

[0103] The mixed material 9 consists of structural ceramic particles 20, metal particles 21, and active solder 22 in a volume ratio of 5.3-5.5:3.5:1-1.2, and a liquid with a mass ratio of 0.05%, which is composed of ethyl acetate, anhydrous ethanol, and distilled water.

[0104] The structural ceramic particles 20 are selected from 10% by weight of alumina ceramic particles with a particle size of 3 mm, 85% by weight of alumina ceramic particles with a particle size of 0.5-0.8 mm, and 5% by weight of alumina ceramic particles with a particle size of 0.1-0.3 mm.

[0105] Metal particles 21 are selected from carbon steel alloy with a particle size of 0.5 to 0.8 mm by weight of 60% and stainless steel with a particle size of 0.5 to 0.8 mm by weight of 40%.

[0106] The active solder 22 is made of a mixture of titanium hydride, titanium and copper powder, wherein the weight ratio of titanium hydride to titanium is 1:1.

[0107] Step 3: Fabricate wear-resistant insert 11;

[0108] Step 3.1: After cleaning the inner wall of the original tube, first seal one end of the closed shrink tube 8, mix the mixed material 9 from step 2 evenly and fill it into the closed shrink tube 8, fill it completely and vibrate it to compact it, then seal the other end of the closed shrink tube 8 and weld the air extraction pipe interface 10 to this end to obtain the closed shrink tube 8; the sealing is done by welding.

[0109] Step 3.2: Place the sealed tube 8 into the low-temperature heating device. First, extract the gas inside the sealed tube 8 through the extraction pipe interface 10. When the vacuum degree inside the sealed tube 8 is close to 3-30 kPa, turn on the low-temperature heating device to heat the sealed tube 8 to 250°C. At the same time, continue to extract the gas inside the sealed tube 8 (including the gas that evaporates or decomposes at high temperature) through the extraction pipe interface 10. When the vacuum degree inside the sealed tube 8 is higher than 3-30 kPa, close the extraction pipe interface 10.

[0110] Step 3.3: Place the sealed shrink tube 8 into a medium-temperature heating device and heat it to the set temperature of 900℃~950℃. Hold it at this temperature for 5 minutes to make the temperature inside and outside the sealed shrink tube 8 uniform. The set temperature is 10℃~100℃ lower than the melting point of the active solder 22.

[0111] Step 3.4: Place the closed shrink tube 8 into the densification extrusion and compression tube unit. The tube shrinking head of different diameter in the densification extrusion and compression tube unit will squeeze and shrink the tube step by step, so that the diameter of the closed shrink tube 8 will gradually decrease and the mixed material 9 inside the closed shrink tube 8 will gradually become dense, reaching the preset density.

[0112] Step 3.5: Place the closed shrink tube 8 into a high-temperature heating device and heat it to 1050℃~1100℃. Keep it at this temperature for 30 minutes to allow the molten active solder 22 to react with the structural ceramic particles 20.

[0113] Step 3.6: Place the closed shrink tube 8 into the forming, extrusion and stretching tube compression unit. As the closed shrink tube 8 gradually cools down, it is simultaneously pressed and shaped by the forming, extrusion and stretching tube compression unit. When the liquid metal inside the closed shrink tube 8 solidifies, an induction heating device is used to locally heat the closed shrink tube 8, while a rotary extrusion device is used to extrude the closed shrink tube 8, causing it to locally shrink and form the wear-resistant insert 11 in the preset shape.

[0114] Step 3.7: Cut and process the closed tube 8 obtained in step 3.6 to obtain the wear-resistant insert 11.

[0115] The medium-temperature heating device in step 3.3 and the high-temperature heating device in step 3.5 are both devices that can simultaneously and orderly insert and output multiple closed constricted tubes 8.

[0116] Example 3

[0117] Reference Figure 1A method for manufacturing a metal-ceramic wear-resistant insert includes the following steps:

[0118] Step 1: Prepare the original tube according to the wear-resistant insert 11;

[0119] In this embodiment, the wear-resistant insert 11 is a corrugated strip with a rectangular cross-section of 32mm wide and 50mm long. The original tube is a Q235 carbon steel tube with a length of 3 meters, an inner diameter of 60mm, and a wall thickness of 1.5mm. In other embodiments, the wall thickness of the original tube can be 1mm to 5mm.

[0120] Step 2: Prepare the mixed ingredients 9;

[0121] The mixed material 9 consists of structural ceramic particles 20, metal particles 21, and active solder 22 in a volume ratio of 4-4.2:3.5-4:1.8-2.5, and a liquid with a mass ratio of 1.5%, which is composed of ethyl acetate, anhydrous ethanol, and distilled water.

[0122] The structural ceramic particles 20 are selected from 95% by weight of alumina ceramic particles with a particle size of 0.5 to 0.8 mm and 5% by weight of silicon carbide ceramic particles with a particle size of 0.3 to 0.5 mm.

[0123] Metal particles 21 are selected from carbon steel alloy particles with a particle size of 0.5 to 0.8 mm;

[0124] Active solder 22 is made from a mixture of titanium, copper, and boron powder;

[0125] Step 3: Fabricate wear-resistant insert 11;

[0126] Step 3.1 After cleaning the inner wall of the original tube, first seal one end of the closed shrink tube 8, mix the mixed material 9 from step 2 evenly and fill it into the closed shrink tube 8, fill it completely and vibrate it to compact it, then seal the other end of the closed shrink tube 8 and weld the air extraction pipe interface 10 to this end to obtain the closed shrink tube 8.

[0127] Step 3.2: Place the sealed tube 8 into the low-temperature heating device. First, extract the gas inside the sealed tube 8 through the extraction pipe interface 10. When the vacuum degree inside the sealed tube 8 is close to 3-30 kPa, turn on the low-temperature heating device to heat the sealed tube 8 to 650°C. At the same time, continue to extract the gas inside the sealed tube 8 (including the gas that evaporates or decomposes at high temperature) through the extraction pipe interface 10. When the vacuum degree inside the sealed tube 8 is higher than 3-30 kPa, close the extraction pipe interface 10.

[0128] Step 3.3: Place the sealed shrink tube 8 into a medium-temperature heating device and heat it to the set temperature of 850℃~900℃. Hold it at this temperature for 5 minutes to make the temperature inside and outside the sealed shrink tube 8 uniform. The set temperature is 10℃~100℃ lower than the melting point of the active solder 22.

[0129] Step 3.4: Place the closed shrink tube 8 into the densification extrusion and compression tube unit. The tube shrinking head with different rectangular cross-sections in the densification extrusion and compression tube unit will squeeze and shrink the tube step by step, so that the diameter of the closed shrink tube 8 will gradually decrease and the mixed material 9 inside the closed shrink tube 8 will gradually become dense, reaching the preset density.

[0130] Step 3.5: Place the closed shrink tube 8 into a high-temperature heating device and heat it to 1050℃~1100℃. Keep it at this temperature for 30 minutes to allow the molten active solder 22 to react with the structural ceramic particles 20.

[0131] Step 3.6: Place the closed shrink tube 8 into the forming extrusion and stretching tube compression unit. As the closed shrink tube 8 gradually cools down, the forming extrusion and stretching tube compression unit simultaneously presses and shapes the closed shrink tube 8. Before the liquid metal inside the closed shrink tube 8 solidifies, the corrugated forming machine in the forming extrusion and stretching tube compression unit extrudes or stretches the shape of the closed shrink tube 8 to form the preset shape of the wear-resistant insert 11.

[0132] Step 3.7: Cut and process the closed tube 8 obtained in step 3.6 to obtain the wear-resistant insert 11.

[0133] Based on the above-mentioned method for manufacturing metal-ceramic wear-resistant inserts, this invention also discloses a method for installing metal-ceramic wear-resistant inserts, comprising the following steps:

[0134] Step 1: Fabricate at least one wear-resistant insert according to the above-described method for manufacturing metal-ceramic wear-resistant inserts;

[0135] Step 2: The wear-resistant inserts obtained in Step 1 are directly embedded or encapsulated in liquid metal and then embedded onto the workpiece to form a semi-finished product. The semi-finished product is then machined and heat-treated to form a finished product, thus completing the embedding process.

[0136] Direct embedding specifically refers to embedding wear-resistant inserts into holes in workpieces by means of heating, interference fit, welding, or bonding.

[0137] The liquid metal encapsulation process involves welding multiple wear-resistant inserts obtained in step 1 together with a steel connecting frame, placing the steel connecting frame with the multiple wear-resistant inserts into a casting mold, and then injecting liquid metal into the casting mold to produce a semi-finished product.

[0138] The following specific embodiments illustrate the method for installing a metal composite ceramic wear-resistant insert according to the present invention:

[0139] Example 1

[0140] Reference Figure 12 A method for installing a metal-ceramic wear-resistant insert includes the following steps:

[0141] The wear-resistant insert 11 is a toothed pin;

[0142] Step 1: Fabricate wear-resistant insert 11 according to the manufacturing method of metal composite ceramic wear-resistant insert described in Example 1;

[0143] Step 2: Place the wear-resistant insert 11 obtained in Step 1 into the center hole of the cutting tooth steel sleeve 30, and weld the wear-resistant insert 11 to the cutting tooth steel sleeve 30 together using brazing (brazing is for easy recycling of the cutting tooth steel sleeve 30). In other embodiments, welding can also be replaced by interference fit or bonding after heating.

[0144] Example 2

[0145] Reference Figure 13 A method for embedding a metal-ceramic wear-resistant insert, used for embedding roller nails inside a pressure roller, includes the following steps:

[0146] The wear-resistant insert 11 is a roller nail with a rectangular cross-section; in other embodiments, the cross-section may also be circular or polygonal.

[0147] Step 1: Fabricate multiple wear-resistant inserts 11 according to the manufacturing method of the metal composite ceramic wear-resistant insert described in Example 1;

[0148] Step 2: Weld the multiple wear-resistant inserts 11 obtained in Step 1 to the steel connecting frame 31 together. The welding is specifically butt welding.

[0149] Step 3: Place the steel connecting frame 31 with multiple wear-resistant inserts 11 into the sand casting mold, then inject liquid metal into the sand casting mold to make a semi-finished product, and then process and heat treat it to make a pressure roller.

[0150] Example 3

[0151] Reference Figure 14 A method for embedding a metal-ceramic wear-resistant insert, used to embed the wear-resistant insert 11 inside a grinding roller, includes the following steps:

[0152] The wear-resistant insert 11 is a wavy strip with a rectangular cross-section;

[0153] Step 1: Fabricate multiple wear-resistant inserts 11 according to the manufacturing method of the metal composite ceramic wear-resistant insert described in Example 1;

[0154] Step 2: Weld the multiple wear-resistant inserts 11 obtained in Step 1 to the steel connecting frame 31 together. The welding is specifically butt welding.

[0155] Step 3: Place the steel connecting frame 31 with multiple wear-resistant inserts 11 into the sand casting mold, then inject liquid metal into the sand casting mold to make a semi-finished product, and then process and heat treat it to make a grinding roller.

[0156] This embodiment is also applicable to adding roller nails to grinding rollers, as well as adding liner nails and liner strips to liners and guard plates.

Claims

1. A method for manufacturing a metal-ceramic wear-resistant insert, characterized in that, Includes the following steps: Step 1: Prepare the base tube for making the corresponding closed shrink tube according to the size of the wear-resistant insert; Step 2: Prepare the mixing materials; The mixed material comprises structural ceramic particles, metal particles, and active solder in a volume ratio of 3.5~5.5:3.5~5.5:1~2.

5. The particle size of the structural ceramic particles is 0.1~3mm; The particle size of the metal particles is 0.3~2mm; The active solder includes an active metal and auxiliary materials, wherein the auxiliary materials include one or a combination of copper, copper alloys, nickel, chromium, and boron. Step 3: After cleaning the inner wall of the original tube, first seal one end of the original tube. Then, mix the materials from Step 2 evenly and fill the original tube completely, compacting it with vibration. Next, seal the other end of the original tube and weld an extraction pipe interface onto it to obtain a sealed shrink tube. The sealed shrink tube is then vacuumed, heated, and extruded to form the preset shape of the wear-resistant insert. Finally, the sealed shrink tube is cut and processed to obtain the wear-resistant insert, specifically as follows: Step 3.1: After cleaning the inner wall of the original tube, first seal one end of the original tube, mix the mixed material from step 2 evenly and fill it into the original tube, then vibrate and compact it. Then seal the other end of the original tube and weld the air extraction pipe interface at this end to obtain a sealed shrink tube. Step 3.2: Place the sealed tube into the low-temperature heating device. First, extract the gas from the sealed tube through the evacuation pipe interface. Then, turn on the low-temperature heating device to heat the sealed tube to 250℃~650℃. At the same time, continue to extract the gas from the sealed tube through the evacuation pipe interface. When the vacuum degree in the sealed tube is lower than 30KPa, close the evacuation pipe interface. Step 3.3: Place the sealed shrink tube into a medium-temperature heating device, heat it to the set temperature, and keep it at that temperature for more than 5 minutes to make the temperature inside and outside the sealed shrink tube equal; the set temperature is 10℃~100℃ below the melting point of the active solder. Step 3.4: Place the closed tube into the densification extrusion tube compression unit. The tube is squeezed and shrunken step by step by different tube shrinking heads in the densification extrusion tube compression unit, so that the size of the closed tube gradually decreases and the mixed material inside the closed tube gradually becomes denser, reaching the preset density. Step 3.5: Place the sealed shrink tube into a high-temperature heating device and heat it to 1050℃~1120℃. Hold it at that temperature for more than 30 minutes to allow the molten active solder to react with the structural ceramic particles. Step 3.6: Place the closed shrink tube into the forming, extrusion and stretching tube unit. As the closed shrink tube gradually cools down, it is simultaneously pressed and shaped by the forming, extrusion and stretching tube unit to form the preset shape of the wear-resistant insert. Step 3.7: Cut and process the closed tube obtained in step 3.6 to obtain the wear-resistant insert.

2. The method for manufacturing a metal-ceramic wear-resistant insert according to claim 1, characterized in that: In step 2, the structural ceramic particles are one or a combination of several of the following: alumina, silicon carbide, titanium carbide-reinforced alumina, silicon carbide-reinforced alumina, boron carbide-reinforced alumina, and titanium carbide-reinforced silicon carbide particles. The metal particles are one or a combination of carbon steel alloy, stainless steel, manganese steel alloy, nickel steel alloy, and chromium steel alloy particles. The active metal includes one or a combination of titanium, titanium alloys, and titanium hydride.

3. A method for manufacturing a metal-ceramic wear-resistant insert according to any one of claims 1 to 2, characterized in that: In step 1, the radial dimension of the inner wall of the original tube is 1.15 to 2 times the dimension of the wear-resistant insert in the corresponding direction, and the wall thickness of the original tube is 1 mm to 5 mm.

4. A method for manufacturing a metal-ceramic wear-resistant insert according to any one of claims 1 to 2, characterized in that: In step 2, the mixed material also includes a liquid, the mass of which is 0.05% to 3% of the mass of the mixed material, and the liquid includes one or a combination of ethyl acetate, anhydrous ethanol, and distilled water.

5. The method for manufacturing a metal-ceramic wear-resistant insert according to claim 1, characterized in that: In step 3.1, one end of the original tube is first sealed, and the other end of the original tube is sealed by local induction heating or by welding.

6. The method for manufacturing a metal composite ceramic wear-resistant insert according to claim 1, characterized in that: The medium-temperature heating device mentioned in step 3.3 and the high-temperature heating device mentioned in step 3.5 are both devices that can simultaneously and orderly insert and output multiple closed constricted tubes.

7. A method for installing a metal-ceramic wear-resistant insert, characterized in that, Includes the following steps: Step 1: Fabricate at least one wear-resistant insert according to the manufacturing method of the metal composite ceramic wear-resistant insert as described in claim 1; Step 2: The wear-resistant inserts obtained in Step 1 are directly embedded or encapsulated in liquid metal and then embedded onto the workpiece to form a semi-finished product. The semi-finished product is then machined and heat-treated to form a finished product, thus completing the embedding process.

8. The method for installing a metal-ceramic wear-resistant insert according to claim 7, characterized in that, In step 2, the direct embedding specifically refers to: Drill holes in the workpiece and then insert wear-resistant inserts into the holes by means of interference fit after heating, welding, or bonding.

9. The method for installing a metal-ceramic wear-resistant insert according to claim 7, characterized in that, In step 2, the liquid metal encapsulation and embedding specifically involves: Weld the multiple wear-resistant inserts obtained in step 1 together with the steel connecting frame, place the steel connecting frame with the multiple wear-resistant inserts into the casting mold, and then inject liquid metal into the casting mold.

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