Carbide reinforced iron-based metal composite material and preparation method thereof

Abstract

The present invention belongs to the technical field of material processing, and specifically relates to a carbide-reinforced iron-based metal composite material and a preparation method thereof. With an iron-based metal as a matrix and carbide as a reinforcing phase, a carbide-reinforced iron-based metal material blank is obtained by printing and molding through a binder injection molding process, and then solidification, degreasing and sintering treatments are performed in sequence. The present invention applies the binder injection technology to the preparation of carbide-reinforced iron-based metal composite materials, which can not only achieve precise control of material composition and structure, but also prepare components with high hardness, high wear resistance and complex structure under low-cost conditions; by means of layer-by-layer bonding, the carbide reinforcing phase is evenly distributed in the iron-based metal matrix, which effectively promotes the interface bonding between the reinforcing phase and the matrix, improves the overall performance of the composite material, and can accurately control the shape and size of the material, reduce material waste, and avoid subsequent complex mechanical processing steps.

Description

Technical Field

[0001] The invention belongs to the technical field of material processing, and in particular relates to a carbide reinforced iron-based metal composite material and a preparation method thereof. Background Art

[0002] Binder jetting technology is an advanced additive manufacturing technology, and its core principle combines the essence of inkjet printing and powder bed printing. This technology precisely controls the spraying of the binder, directly acting on the pre-laid powder material layer (such as metal, ceramic, polymer, etc.), and uses the selective curing effect of the binder to bond and stack the powder particles layer by layer to form a preliminary printed body. This process is carried out at room temperature, avoiding the solid-liquid phase transition and the accompanying heat transfer problems, thereby effectively eliminating the possibility of residual stress and thermal stress accumulation, and significantly improving the dimensional stability and processing accuracy of the product.

[0003] The main advantage of binder jetting technology lies in the flexibility and economy of its printing process. On the one hand, the technology does not require additional support structures, which greatly liberates design constraints, making it possible to achieve complex geometries and high-precision details, and broadens its application potential in high-end manufacturing fields such as aerospace, automotive manufacturing, medical devices and electronic equipment. On the other hand, since no special atmosphere or high energy source input is required during the printing process, the operating cost of binder jetting equipment is relatively low, which has more significant economic advantages than other additive manufacturing technologies.

[0004] In the field of metal matrix composites, especially iron-based metal composites, the hardness and wear resistance of materials can be significantly improved by introducing reinforcing phases, which is an effective way to improve material performance and extend service life. Carbides are one of the ideal reinforcements in metal matrix composites due to their high strength, high hardness and good thermal stability. However, traditional preparation processes often face problems such as long preparation cycles, high energy consumption, and low material utilization, which limits their application in large-scale production and the manufacture of complex structural parts. Summary of the invention

[0005] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a carbide reinforced iron-based metal composite material, and to apply binder spraying technology to the preparation of carbide reinforced iron-based metal composite materials, which can not only achieve precise control of material composition and structure, but also can prepare components with high hardness, high wear resistance and complex structure under low cost conditions.

[0006] Another object of the present invention is to provide a method for preparing a carbide-reinforced iron-based metal composite material, which uniformly distributes the carbide reinforcement phase in the iron-based metal matrix by layer-by-layer bonding, effectively promotes the interface bonding between the reinforcement phase and the matrix, and improves the overall performance of the composite material. At the same time, the preparation method can accurately control the shape and size of the material, reduce material waste, and avoid subsequent complex mechanical processing steps. This not only improves production efficiency, but also significantly reduces production costs and energy consumption.

[0007] The technical solution adopted by the present invention is as follows:

[0008] The carbide reinforced iron-based metal composite material has an iron-based metal as a matrix and carbide as a reinforcement phase. The carbide reinforced iron-based metal material blank is printed and formed by a binder injection molding process. The carbide reinforced iron-based metal material blank is sequentially cured, degreased and sintered to obtain the carbide reinforced iron-based metal composite material; wherein the amount of carbide is 1-10wt.% of the total amount of the iron-based metal;

[0009] The iron-based metal is one of cast iron, carbon steel or alloy steel;

[0010] The carbide is one of silicon carbide, tungsten carbide or boron carbide.

[0011] The particle size of the iron-based metal is 5-55 μm.

[0012] The particle size of the carbide is 70-210 nm.

[0013] The method for preparing the carbide reinforced iron-based metal composite material comprises the following steps:

[0014] (1) Mixing the iron-based metal and the carbide and placing them in a ball mill for ball milling to obtain a mixed powder;

[0015] (2) Using 3D modeling software to construct a 3D model, and then uploading the model to the control system of the binder jet 3D printer;

[0016] (3) Setting the parameters of the binder jet 3D printer to print the mixed powder layer by layer to obtain a carbide-reinforced iron-based metal material blank;

[0017] (4) curing the carbide reinforced iron-based metal material blank to ensure that the blank has sufficient strength;

[0018] (5) The solidified carbide reinforced iron-based metal material blank is placed in a vacuum degreasing and sintering furnace for degreasing and sintering to obtain a carbide reinforced iron-based metal composite material.

[0019] In the step (1), the ball-to-material ratio is 1:2, the rotation speed is 180-200 rpm, and the ball milling time is 2-10 hours.

[0020] In the step (3), the parameters of the 3D printer are: powder spreading speed 20~80mm / s, drying time 5~10s, fine roller speed 150~200rpm, coarse roller speed 50~80rpm, roller moving speed 2~6mm / s, binder saturation 80~100%, and heat output power 80~100%.

[0021] In the step (4), the curing is thermal curing, the curing temperature is 150-200°C, and the curing time is 6-10 hours.

[0022] In the step (5), the degreasing temperature is 500-800°C and the temperature is kept for 1-2 hours.

[0023] In the step (5), the sintering temperature is 1150-1350°C and the temperature is kept for 1-2 hours.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] (1) The carbide-reinforced iron-based metal composite material of the present invention induces super solid phase sintering by introducing an appropriate amount of carbide particles into the iron-based metal matrix. In this process, the generation of local liquid phase not only effectively fills the pores in the blank and significantly reduces the porosity, but also promotes the close bonding and diffusion between the matrix and the reinforcement phase, realizes the densification and strengthening of the material microstructure, thereby greatly improving the mechanical properties of the composite material, especially the hardness and wear resistance;

[0026] (2) The carbide-reinforced iron-based metal composite material described in the present invention significantly strengthens the iron-based metal matrix by introducing nano-scale carbide particles as a reinforcing phase and utilizing their high specific surface area and excellent physical and chemical properties. The uniform dispersion of nanoparticles in the matrix not only effectively hinders the propagation of cracks, but also improves the hardness and wear resistance of the overall material through interface strengthening, so that the composite material exhibits excellent performance stability and service life under extreme working conditions;

[0027] (3) The preparation method of the carbide reinforced iron-based metal composite material described in the present invention adopts binder injection molding technology, which breaks the limitations of traditional manufacturing methods and realizes the unsupported direct printing of parts with complex geometric shapes. At the same time, the preparation method can accurately control the shape, size and thickness of the material, reduce material waste, and avoid subsequent complex mechanical processing steps, which not only improves production efficiency, but also significantly reduces production costs and energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 XRD diagrams of the tungsten carbide, the carbide-reinforced iron-based metal material blank and the carbide-reinforced iron-based metal composite material in Example 1;

[0029] Figure 2 The metallographic image of the AM40 die steel in Example 2 (×100 times);

[0030] Figure 3 This is the metallographic image of the carbide reinforced iron-based metal composite material in Example 2 (×100 times). DETAILED DESCRIPTION

[0031] The present invention is further described below with reference to the embodiments, but they do not limit the implementation of the present invention.

[0032] The raw materials used in the examples and comparative examples are conventional commercially available raw materials unless otherwise specified, and the process methods used in the examples and comparative examples are conventional methods in the art unless otherwise specified.

[0033] Some of the raw materials used in the examples and comparative examples are described as follows:

[0034] AM40 die steel, purchased from Sino-Kebrafe Materials Technology (Dongguan) Co., Ltd., is alloy steel;

[0035] 8620 low alloy steel, purchased from Sino-Kebrafe Materials Technology (Dongguan) Co., Ltd., is alloy steel;

[0036] Gray cast iron HT200 was purchased from Sino-Kebrafe Materials Technology (Dongguan) Co., Ltd. and is cast iron.

[0037] Example 1

[0038] The method for preparing the carbide reinforced iron-based metal composite material comprises the following steps:

[0039] (1) AM40 mold steel with a particle size of 20±3µm and tungsten carbide with a particle size of 75±5nm were mixed and placed in a ball mill for ball milling to obtain a mixed powder; the ball-to-material ratio was 1:2, the amount of tungsten carbide was 6wt.% of the total amount of AM40 mold steel, the rotation speed was 200rpm, and the ball milling time was 10h;

[0040] (2) Using 3D modeling software to construct a 3D model, and then uploading the model to the control system of the binder jet 3D printer;

[0041] (3) Setting the parameters of the binder jetting 3D printer, printing the mixed powder layer by layer, and obtaining a carbide-reinforced iron-based metal material blank; the parameters of the 3D printer are: powder spreading speed 60 mm / s, drying time 10 s, fine roller speed 200 rpm, coarse roller speed 80 rpm, roller moving speed 2 mm / s, binder saturation 100%, and heat output power 100%;

[0042] (4) curing the carbide reinforced iron-based metal material blank, wherein the curing is thermal curing, the curing temperature is 150° C., and the curing time is 10 h;

[0043] (5) The solidified carbide-reinforced iron-based metal material blank is placed in a vacuum degreasing and sintering furnace for degreasing and sintering to obtain a carbide-reinforced iron-based metal composite material. The degreasing temperature is 500°C and the temperature is kept for 2 hours; the sintering temperature is 1350°C and the temperature is kept for 1 hour.

[0044] The XRD diffractometer was used to analyze the physical phases of tungsten carbide (WC), carbide-reinforced iron-based metal material blank (WC+BJ) and carbide-reinforced iron-based metal composite material (WC+sintering). Figure 1 As shown, the results show that the diffraction peak intensity of tungsten carbide decreases after sintering.

[0045] Example 2

[0046] The method for preparing the carbide reinforced iron-based metal composite material comprises the following steps:

[0047] (1) AM40 mold steel with a particle size of 20±3µm and silicon carbide with a particle size of 75±5nm were mixed and placed in a ball mill for ball milling to obtain a mixed powder; the ball-to-material ratio was 1:2, the amount of silicon carbide was 1wt.% of the total amount of AM40 mold steel, the rotation speed was 200rpm, and the ball milling time was 2h;

[0048] (2) Using 3D modeling software to construct a 3D model, and then uploading the model to the control system of the binder jet 3D printer;

[0049] (3) Setting the parameters of the binder jetting 3D printer, printing the mixed powder layer by layer, and obtaining a carbide-reinforced iron-based metal material blank; the parameters of the 3D printer are: powder spreading speed 60 mm / s, drying time 8 s, fine roller speed 185 rpm, coarse roller speed 60 rpm, roller moving speed 3 mm / s, binder saturation 90%, and heat output power 90%;

[0050] (4) curing the carbide reinforced iron-based metal material blank, wherein the curing is thermal curing, the curing temperature is 160° C., and the curing time is 8 h;

[0051] (5) The solidified carbide-reinforced iron-based metal material blank is placed in a vacuum degreasing and sintering furnace for degreasing and sintering to obtain a carbide-reinforced iron-based metal composite material. The degreasing temperature is 600°C and the temperature is kept for 1.5 hours; the sintering temperature is 1150°C and the temperature is kept for 2 hours.

[0052] The microstructures of AM40 die steel and the prepared carbide reinforced iron-based metal composites were observed using an optical microscope. Figure 2~3 As shown. Figure 2 It can be seen that the holes in AM40 mold steel are numerous and large. Figure 3 It can be seen that the pores of the prepared carbide reinforced iron-based metal composite material are significantly reduced, indicating that the density of the prepared carbide reinforced iron-based metal composite material is effectively improved by adopting the preparation method of the carbide reinforced iron-based metal composite material described in the present invention.

[0053] Example 3

[0054] The method for preparing the carbide reinforced iron-based metal composite material comprises the following steps:

[0055] (1) 8620 low alloy steel with a particle size of 50±5µm and boron carbide with a particle size of 200±10nm were mixed and placed in a ball mill for ball milling to obtain a mixed powder; the ball-to-material ratio was 1:2, the amount of boron carbide was 10wt.% of the total amount of 8620 low alloy steel, the rotation speed was 180rpm, and the ball milling time was 4h;

[0056] (2) Using 3D modeling software to construct a 3D model, and then uploading the model to the control system of the binder jet 3D printer;

[0057] (3) Setting the parameters of the binder jetting 3D printer, printing the mixed powder layer by layer, and obtaining a carbide-reinforced iron-based metal material blank; the parameters of the 3D printer are: powder spreading speed 80 mm / s, drying time 5 s, fine roller speed 200 rpm, coarse roller speed 60 rpm, roller moving speed 6 mm / s, binder saturation 80%, and heat output power 100%;

[0058] (4) curing the carbide reinforced iron-based metal material blank, wherein the curing is thermal curing, the curing temperature is 200° C., and the curing time is 6 h;

[0059] (5) The solidified carbide-reinforced iron-based metal material blank is placed in a vacuum degreasing and sintering furnace for degreasing and sintering to obtain a carbide-reinforced iron-based metal composite material. The degreasing temperature is 600°C and the temperature is kept for 1.5 hours; the sintering temperature is 1350°C and the temperature is kept for 2 hours.

[0060] Example 4

[0061] The method for preparing the carbide reinforced iron-based metal composite material comprises the following steps:

[0062] (1) Gray cast iron HT200 with a particle size of 10±5µm and silicon carbide with a particle size of 75±5nm were mixed and placed in a ball mill for ball milling to obtain a mixed powder; the ball-to-material ratio was 1:2, the amount of silicon carbide was 5wt.% of the total amount of gray cast iron HT200, the rotation speed was 200rpm, and the ball milling time was 6h;

[0063] (2) Using 3D modeling software to construct a 3D model, and then uploading the model to the control system of the binder jet 3D printer;

[0064] (3) Setting the parameters of the binder jetting 3D printer, printing the mixed powder layer by layer, and obtaining a carbide-reinforced iron-based metal material blank; the parameters of the 3D printer are: powder spreading speed 20 mm / s, drying time 10 s, fine roller speed 150 rpm, coarse roller speed 50 rpm, roller moving speed 6 mm / s, binder saturation 90%, and heat output power 80%;

[0065] (4) curing the carbide reinforced iron-based metal material blank, wherein the curing is thermal curing, the curing temperature is 180° C., and the curing time is 8 h;

[0066] (5) The solidified carbide-reinforced iron-based metal material blank is placed in a vacuum degreasing and sintering furnace for degreasing and sintering to obtain a carbide-reinforced iron-based metal composite material. The degreasing temperature is 800°C and the temperature is kept for 1 hour; the sintering temperature is 1350°C and the temperature is kept for 1 hour.

[0067] Comparative Example 1

[0068] The difference from Example 1 is that the amount of tungsten carbide used is 0.02wt.% of the total amount of AM40 mold steel, and the rest is the same as Example 1.

[0069] Comparative Example 2

[0070] The difference from Example 1 is that the amount of tungsten carbide used is 20wt.% of the total amount of AM40 mold steel, and the rest is the same as Example 1.

[0071] The composite materials prepared in Examples 1 to 4 and Comparative Examples 1 to 2 were tested for performance, and the testing methods were as follows:

[0072] Hardness: Tested in accordance with GB / T 4340.1-2009;

[0073] Porosity: Tested in accordance with GB / T 43101-2023;

[0074] Quality wear: Tested in accordance with GB / T 12444.1-1990, using MMW-1 friction and wear testing machine, with a test force of 150N, a rotation speed of 300rpm, and a test time of 20min to measure the wear amount.

[0075] The test results are shown in Table 1.

[0076] Table 1 Performance test results

[0077]

[0078] It can be seen from the data in Table 1 that the carbide-reinforced iron-based metal composite materials prepared in Examples 1 to 4 have a hardness of ≥302.71 Hv, a porosity of ≤5.66%, and a mass wear of ≤30 mg, indicating that the hardness and wear resistance of the iron-based metal material are improved by introducing nano-scale carbide particles as a reinforcing phase. Compared with Example 1, Comparative Example 1 has a reduced performance due to the small amount of tungsten carbide used, which makes it difficult to significantly strengthen the iron-based metal matrix. Compared with Example 1, Comparative Example 2 has a reduced performance due to the increased brittleness of the iron-based metal matrix caused by the introduction of too much tungsten carbide.

Claims

1. A carbide reinforced iron-based metal composite material, characterized in that: With iron-based metal as the matrix and carbide as the reinforcement phase, a carbide-reinforced iron-based metal material blank is obtained by printing through a binder injection molding process, and the carbide-reinforced iron-based metal material blank is sequentially cured, degreased and sintered to obtain a carbide-reinforced iron-based metal composite material; wherein the amount of carbide is 1-10wt.% of the total amount of the iron-based metal; The iron-based metal is one of 8620 low alloy steel or gray cast iron HT200; The carbide is one of silicon carbide, tungsten carbide or boron carbide; The particle size of the carbide is 70-210 nm; The method for preparing the carbide reinforced iron-based metal composite material comprises the following steps: (1) Mixing the iron-based metal and the carbide and placing them in a ball mill for ball milling to obtain a mixed powder; (2) Using 3D modeling software to construct a 3D model, and then uploading the model to the control system of the binder jet 3D printer; (3) Setting the parameters of the binder jet 3D printer to print the mixed powder layer by layer to obtain a carbide-reinforced iron-based metal material blank; (4) curing the carbide reinforced iron-based metal material blank; (5) placing the solidified carbide-reinforced iron-based metal material blank into a vacuum degreasing and sintering furnace for degreasing and sintering to obtain a carbide-reinforced iron-based metal composite material; The binder saturation is 80-100%; The degreasing temperature is 500-800°C.

2. The carbide reinforced iron-based metal composite material according to claim 1, characterized in that: The particle size of the iron-based metal is 5-55 μm.

3. The carbide reinforced iron-based metal composite material according to claim 1, characterized in that: In the step (1), the rotation speed is 180-200 rpm and the ball milling time is 2-10 h.

4. The carbide reinforced iron-based metal composite material according to claim 1, characterized in that: In the step (3), the parameters of the 3D printer are: powder spreading speed 20~80mm / s, drying time 5~10s, fine roller speed 150~200rpm, coarse roller speed 50~80rpm, roller moving speed 2~6mm / s, and heat output power 80~100%.

5. The carbide reinforced iron-based metal composite material according to claim 1, characterized in that: In the step (4), the curing is thermal curing, the curing temperature is 150-200°C, and the curing time is 6-10 hours.

6. The carbide reinforced iron-based metal composite material according to claim 1, characterized in that: In the step (5), the temperature is kept at 1 to 2 hours.

7. The carbide reinforced iron-based metal composite material according to claim 1, characterized in that: In the step (5), the sintering temperature is 1150-1350°C and the temperature is kept for 1-2 hours.

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