Carbide particle reinforced Ni3Al alloy and application thereof

Abstract

The invention belongs to the technical field of wear-resistant coating preparation, and relates to a carbide particle reinforced Ni3Al alloy and application thereof. The alloy comprises the following components in percentage by mass: 49%-53% of Cr, 4.3%-4.8% of Al, 4.2%-4.9% of C, 0.02%-0.05% of B, less than or equal to 10ppm of H and the balance of Ni. The carbide content of chromium in the carbide particle reinforced Ni3Al alloy is 48 wt%-52 wt%. Dry carbide particle reinforced Ni3Al alloy powder serves as a raw material, the alloy powder is sprayed to a treated base material through a supersonic flame spraying method with proper parameters, and the coating is obtained. According to the preparation method, the alloy powder is self-generated in situ in the Ni3Al alloy melt through chromium carbide, so that the uniformity and the fluidity of the powder are improved; and meanwhile, Ni3Al-based alloy powder is sprayed to the surface of the base material through thermal spraying with proper parameters, the problem that a cladding layer is prone to cracking is solved, and the hardness, abrasion resistance and crack resistance of the cladding layer are remarkably improved.

Description

Technical Field

[0001] The invention belongs to the technical field of wear-resistant coating preparation and relates to a carbide particle reinforced Ni3Al alloy and application thereof. Background Art

[0002] Metal ceramic coatings are widely used in high-end equipment, energy, aerospace and other fields due to their high strength, high toughness and good processing performance. Among them, Ni3Al, as an intermetallic compound, has received widespread attention in the industry due to its low density, high melting point, high-temperature oxidation resistance and wear resistance. However, the crack resistance of Ni3Al alloy is poor, especially when Ni3Al is added with ceramic reinforcement phase to further enhance the mechanical properties, the crack resistance of Ni3Al-based metal ceramics is even worse, so that Ni3Al+ceramic reinforcement phase (generally CrC with good wettability with Ni3Al) cannot be brought into play. Existing patents disclose Ni3Al-based alloy powders and their application methods, which have a low average hardness and are difficult to be applied to high wear-resistant occasions due to poor crack resistance. For example, the patent with the publication number: CN1603446A and the invention name: A carbide-reinforced nickel-aluminum-based composite high-temperature wear-resistant material involves a carbide Ni3Al-based reinforced composite high-temperature wear-resistant material. The specific chemical composition weight percentage of the high-temperature wear-resistant material is: Al6-14%; Fe1-15%; B0.01-0.1%; carbide 15-35%, wherein carbide refers to any one of chromium carbide, tungsten carbide, and silicon carbide, and the balance is Ni. In this technology, carbide is introduced into the material in an external form, and the hardness of the resulting product at room temperature is only 435~580Hv. At the same time, this technology also records how to simultaneously improve the hardness and wear resistance of the product. Summary of the invention

[0003] In view of the shortcomings of the prior art, the present invention proposes a technology for strengthening Ni3Al alloy by using in-situ generated carbide particles, and attempts to develop a process for preparing an excellent coating by thermal spraying a powdered product.

[0004] The present invention uses chromium carbide to self-generate alloy powder in situ in a Ni3Al alloy melt, thereby improving the uniformity and fluidity of the powder; at the same time, a thermal spraying method is used to spray the Ni3Al-based alloy powder onto a substrate surface, thereby improving the problem that conventional laser cladding methods easily cause cracking of the cladding layer, and significantly improving the hardness, wear resistance and crack resistance of the coating.

[0005] The technical solution adopted by the present invention to solve the above technical problems includes: a carbide particle reinforced Ni3Al alloy, wherein the mass percentages of the components of the alloy are: Cr: 49% to 53%, Al: 4.3% to 4.8%, C: 4.2% to 4.9%, B: 0.02% to 0.05%, H≤10ppm, Ni: balance; The chromium carbide content in the carbide particle reinforced Ni3Al alloy is 48wt% to 52wt%.

[0006] Preferably, the mass percentages of the components of the alloy are: Cr: 50% to 52%, Al: 4.4% to 4.7%, C: 4.4% to 4.8%, B: 0.02% to 0.035%, H≤10ppm, Ni: balance.

[0007] As a further preference, the mass percentages of the components of the alloy are: Cr: 51% to 52%, Al: 4.4% to 4.6%, C: 4.5% to 4.6%, B: 0.025% to 0.035%, H≤5ppm, Ni: balance. This includes Cr: 51%, Al: 4.5%, C: 4.6%, B: 0.025%, H: 5ppm, Ni: balance. It also includes Cr: 51.2%, Al: 4.5%, C: 4.5%, B: 0.035%, H: 3ppm, Ni: balance and other solutions.

[0008] The invention discloses a carbide particle reinforced Ni3Al alloy, and its occurrence form includes one of a block and a particle.

[0009] The powdered carbide particle reinforced Ni3Al alloy has a particle size of 15um to 53um, preferably 15um to 45um.

[0010] The present invention discloses a carbide particle reinforced Ni3Al alloy, wherein element powders are dispensed according to the design composition; and the powder is prepared by a vacuum induction atomization method. Specifically, each metal element and a nickel-boron alloy (the boron content in the nickel-boron alloy is 17% to 19%) are melted and refined in a medium frequency induction furnace, the vacuum degree is ≤10Pa, the temperature is raised to 1300°C at a heating rate of 20°C / min to 30°C / min, and then the temperature is raised to 1600°C to 1700°C at a heating rate of 5°C / min to 10°C / min, and the temperature is kept at 1600°C to 1650°C, and the alloy solution is poured into a tundish through an atomizer to an atomizing tank; specifically, the diameter of the atomizing nozzle is 2mm to 6mm, and the atomizing gas is high-purity nitrogen or argon; the cone angle of the retractable annular gap nozzle is 50° to 70°, and the atomizing pressure is 3MPa to 4.5MPa.

[0011] The invention discloses an application of a carbide particle reinforced Ni3Al alloy, comprising using dried carbide particle reinforced Ni3Al alloy powder as raw material, spraying the alloy powder onto a processed substrate by a supersonic flame spraying method to obtain a coating; the particle size of the carbide particles in the raw material is smaller than the particle size of the raw material powder. When the coating is prepared by supersonic flame spraying, the oxygen flow rate is 735L / min to 835L / min, the kerosene flow rate is 22L / h to 24L / h; the powder feeding amount is 25g / min to 40g / min, the spraying distance is 320mm to 380mm, and the spray gun moving speed is 400mm / s to 800mm / s.

[0012] The material of the substrate is a metal material or a metal ceramic material, and the metal material includes one of carbon steel, stainless steel, aluminum alloy, and copper alloy.

[0013] Before spraying, the roughness of the substrate surface is 60-100 microns, preferably 70-85 microns.

[0014] Preferably, when preparing the coating by supersonic flame spraying, the oxygen flow rate is 765L / min~835L / min, the kerosene flow rate is 20L / h~24L / h; the powder feeding amount is 30g / min~40g / min, the spraying distance is 350mm~360mm, and the spray gun moving speed is 500mm / s~650mm / s.

[0015] The present invention sprays the alloy powder onto the treated metal material surface by a supersonic flame spraying method, thereby solving the problem of easy cracking of Ni3Al alloy powder with high carbide content in the original method (laser cladding, plasma surfacing, etc.), and realizes a high degree of combination of Ni3Al intermetallic compound + ceramic hard phase to meet the use requirements.

[0016] The invention discloses an application of carbide particle reinforced Ni3Al alloy, wherein a drying oven is used to perform preliminary drying treatment on carbide particle reinforced Ni3Al alloy powder. When used in industry, the drying oven temperature is set at 60-85°C and the drying time is 1 h to 3 h.

[0017] The invention discloses an application of carbide particle reinforced Ni3Al alloy. The surface of the substrate is sandblasted, cleaned and dried to obtain a substrate with a surface roughness of 60um to 100um, preferably 70 to 85 microns, for standby use.

[0018] The invention discloses an application of carbide particle reinforced Ni3Al alloy. In the obtained coating, the carbide particles are uniform and fine, and the average particle size is less than 10um, preferably 1um to 5um.

[0019] When the thickness of the coating is 0.02mm~0.04mm; the average hardness of the coating is 700HV~800HV, the friction coefficient is 0.4~0.5, and the wear rate is ≤3.11×10 -5 mm 3 / (N•m).

[0020] After optimization, when the coating thickness is 0.025 mm to 0.035 mm, the average hardness of the coating is 730 HV to 750 HV, the friction coefficient is 0.4 to 0.5, and the wear rate is ≤3.0×10 -5 mm 3 / (N•m).

[0021] The substrate with the coating can be used as a rotary engine. When used as a rotary engine, its service life is much higher than that of the prior art, and can even be higher by 100 hours to 200 hours.

[0022] The present invention has the following beneficial effects: 1) The carbide particle reinforced Ni3Al alloy powder of the present invention has uniform composition and good sphericity; 2) The carbide particle reinforced Ni3Al alloy powder of the present invention has a high content of carbide reinforcement phase, and the coating prepared by using the carbide particle reinforced Ni3Al alloy powder of the present invention has high hardness and excellent wear resistance; 3) The coating prepared by the carbide particle reinforced Ni3Al alloy powder of the present invention has a dense structure, low porosity (≤0.63%), good seismic crack resistance, and can meet the application requirements of components under high temperature and high stress conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The drawings are only for the purpose of illustrating specific embodiments and are not to be construed as limiting the present invention.

[0024] Figure 1 The SEM morphology of the carbide particle reinforced Ni3Al alloy powder obtained in Example 1; Figure 2 This is the interface metallographic morphology of the thermal spray coating of the carbide particle reinforced Ni3Al alloy powder obtained in Example 3.

[0025] from Figure 1 It can be seen that the carbide particle reinforced Ni3Al alloy powder has good sphericity and a relatively uniform particle size distribution.

[0026] from Figure 2 It can be seen that carbides are dispersed in the Ni3Al alloy matrix in the form of fine particles. DETAILED DESCRIPTION

[0027] The present invention will be further described in detail below by way of examples. The following examples are provided to explain the present invention but the present invention is not limited to the following examples.

[0028] Combined with Figures 1-2 The carbide particle-reinforced Ni3Al alloy powder of the present invention comprises the following components in percentage by mass: Cr: 50% to 52%, Al: 4.4% to 4.7%, C: 4.4% to 4.8%, B: 0.02% to 0.035%, H≤10ppm, Ni: balance; the high carbon content forms a high content of carbides in the alloy powder, which significantly improves the hardness and wear resistance of the powder itself and the coating.

[0029] The present invention discloses a method for preparing Ni3Al alloy powder reinforced with carbide particles, wherein element powders are dispensed according to the design composition; and the powder is prepared by vacuum induction atomization. Specifically, each metal element and nickel-boron alloy (boron content in nickel-boron alloy is 17% to 19%) are melted and refined in a medium frequency induction furnace, the vacuum degree is ≤10Pa, the temperature is increased to 1300°C at a heating rate of 20°C / min to 30°C / min, and then the temperature is increased to 1600°C to 1700°C at a heating rate of 5°C / min to 10°C / min, and the temperature is kept at 1600°C to 1650°C, and the alloy solution is poured into the tundish through the atomizer to the atomizing tank; specifically, the diameter of the atomizing nozzle is 2mm to 6mm, and the atomizing gas is high-purity nitrogen or argon; the cone angle of the retractable annular gap nozzle is 50° to 70°, and the atomizing pressure is 3MPa to 4.5MPa. After atomization, the particles are sieved to obtain a particle size of 15um to 53um, which is used as the raw material for subsequent spraying.

[0030] The thermal spraying application of carbide particle reinforced Ni3Al alloy powder of the present invention comprises the following steps: 1) Carbide particle reinforced Ni3Al alloy powder was pre-dried in an oven at 80°C for 2 hours; 2) Use the powder feeder in the supersonic flame spraying equipment to send the above alloy powder to the spray gun, set certain spraying parameters, start ignition-powder feeding-spraying-cooling-spraying, and form a carbide particle reinforced Ni3Al alloy coating on the surface of the treated metal material. Specifically, in order to ensure the quality of the coating, the spraying parameters need to be strictly controlled.

[0031] Specifically, the particle size range of carbide particle reinforced Ni3Al alloy powder is 15um to 53um; the oxygen flow rate is 733L / min to 800L / min, the kerosene flow rate is 20L / h to 24L / h; the powder feeding amount is 25g / min to 40g / min, the spraying distance is 320mm to 380mm, and the spray gun moving speed is 400 to 800mm / s; the spraying process ensures that the surface temperature of the sprayed metal is 50°C to 150°C; Specifically, the thickness of the coating of carbide particle reinforced Ni3Al alloy powder is 0.02 mm to 0.04 mm; Specifically, the average hardness of the coating of carbide particle reinforced Ni3Al alloy powder is 700HV-800HV, the friction coefficient is 0.4-0.5, and the wear rate is ≤3.11×10 -5 mm 3 / (N•m).

[0032] Example 1 The mass percentages of the carbide particle reinforced Ni3Al alloy powder in this embodiment are: Cr: 51%, Al: 4.5%, C: 4.6%, B: 0.025%, H: 5ppm, Ni: balance; the carbide particle reinforced Ni3Al alloy powder (powder particle size is 15um-53um) is used to perform supersonic flame spraying on 304 stainless steel (surface roughness is 80um), the spraying distance is 360mm, the oxygen flow rate is 767L / min, the kerosene flow rate is 24L / h, the powder feeding amount is 30g / min, the spray gun moving speed is 600mm / s, and the sprayed metal surface is 50℃~140℃ during the entire spraying process; In this embodiment, the coating thickness is 0.25 mm, and the average hardness of the coating is 730 HV1; under the condition that the grinding material is SiN (temperature 180 ° C, load 5N, wear radius 6mm, time 1h, speed 1130r / min), the wear rate of the coating is 2.89×10 - 5 mm 3 / (N•m), friction coefficient is 0.47.

[0033] Example 2 In this embodiment, the mass percentages of the carbide particle reinforced Ni3Al alloy powder are: Cr: 50.5%, Al: 4.7%, C: 4.4%, B: 0.03%, H: 4ppm, Ni: balance; the carbide particle reinforced Ni3Al alloy powder is used to perform supersonic flame spraying on 45# steel (surface roughness is 75um), the spraying distance is 350mm, the oxygen flow rate is 800L / min, the kerosene flow rate is 22L / h, the powder feeding amount is 35g / min, the spray gun moving speed is 500mm / s, and the sprayed metal surface is 60℃~150℃ during the entire spraying process; In this embodiment, the coating thickness is 0.30 mm, and the average hardness of the coating is 721 HV1; under the condition that the grinding material is SiN (temperature 180 ° C, load 5N, wear radius 6mm, time 1h, speed 1130r / min), the wear rate of the coating is 3.11×10 - 5 mm 3 / (N•m), friction coefficient is 0.43.

[0034] Example 3 In this embodiment, the mass percentages of the carbide particle reinforced Ni3Al alloy powder are: Cr: 51.2%, Al: 4.5%, C: 4.5%, B: 0.035%, H: 3ppm, Ni: balance; the carbide particle reinforced Ni3Al alloy powder is used to perform supersonic flame spraying on a 4-series aluminum alloy (surface roughness of 70um), the spraying distance is 350mm, the oxygen flow rate is 833L / min, the kerosene flow rate is 24L / h, the powder feeding amount is 40g / min, the spray gun moving speed is 650mm / s, and the sprayed metal surface is 60℃~140℃ during the entire spraying process; In this embodiment, the coating thickness is 0.35 mm, and the average hardness of the coating is 750 HV1; under the condition that the grinding material is SiN (temperature 180 ° C, load 5N, wear radius 6mm, time 1h, speed 1130r / min), the wear rate of the coating is 2.94×10 - 5 mm 3 / (N•m), friction coefficient is 0.44.

[0035] Comparative Example 1 Other conditions are the same as those in Example 3, except that: The mass percentages of carbide particle reinforced Ni3Al alloy powder are: Cr: 33%, Al: 7.3%, C: 3%, B: 0.035%, H: 3ppm, Ni: balance; The coating thickness is 0.33 mm, and the average hardness of the coating is 524 HV1. Under the condition that the counter-grinding material is SiN (temperature 180 ° C, load 5 N, wear radius 6 mm, time 1 h, speed 1130 r / min), the wear rate of the coating is 6.44×10 -5 mm 3 / (N•m), friction coefficient is 0.62.

[0036] Comparative Example 2 The other conditions were the same as those in Example 3, except that the spraying distance was 400 mm, the oxygen flow rate was 850 L / min, the kerosene flow rate was 23 L / h, the powder feeding amount was 30 g / min, the spray gun moving speed was 500 mm / s, and the sprayed metal surface was 60° C. to 150° C. during the entire spraying process; In this comparative example, the coating thickness is 0.34 mm, and the average hardness of the coating is 646 HV1; under the condition that the grinding material is SiN (temperature 180 ° C, load 5N, wear radius 6mm, time 1h, speed 1130r / min), the wear rate of the coating is 6.08×10 - 5 mm 3 / (N•m), friction coefficient is 0.58.

[0037] Comparative Example 3 The other conditions were the same as those in Example 3, except that the spraying distance was 380 mm, the oxygen flow rate was 700 L / min, the kerosene flow rate was 20 L / h, the powder feeding amount was 35 g / min, the spray gun moving speed was 500 mm / s, and the sprayed metal surface was 60° C. to 180° C. during the entire spraying process; The coating thickness is 0.36 mm, and the average hardness of the coating is 581 HV1. Under the condition that the grinding material is SiN (temperature 180 ° C, load 5N, wear radius 6mm, time 1h, speed 1130r / min), the wear rate of the coating is 6.49×10 -5 mm 3 / (N•m), friction coefficient is 0.61.

Claims

1. A carbide particle reinforced Ni3Al alloy, characterized in that: The mass percentages of the alloy components are: Cr: 49% to 53%, Al: 4.3% to 4.8%, C: 4.2% to 4.9%, B: 0.02% to 0.05%, H≤10ppm, Ni: balance; The chromium carbide content in the carbide particle reinforced Ni3Al alloy is 48wt% to 52wt%.

2. The carbide particle reinforced Ni3Al alloy according to claim 1, characterized in that: The mass percentages of the components of the alloy are: Cr: 50% to 52%, Al: 4.4% to 4.7%, C: 4.4% to 4.8%, B: 0.02% to 0.035%, H≤10ppm, and Ni: balance.

3. The carbide particle reinforced Ni3Al alloy according to claim 2, characterized in that: The mass percentages of the alloy components are: Cr: 51% to 52%, Al: 4.4% to 4.6%, C: 4.5% to 4.6%, B: 0.025% to 0.035%, H≤5ppm, Ni: balance. This includes Cr: 51%, Al: 4.5%, C: 4.6%, B: 0.025%, H: 5ppm, Ni: balance. It also includes Cr: 51.2%, Al: 4.5%, C: 4.5%, B: 0.035%, H: 3ppm, Ni: balance and other solutions.

4. The carbide particle reinforced Ni3Al alloy according to claim 1, characterized in that: The powdered carbide particle reinforced Ni3Al alloy has a particle size of 15um to 53um, preferably 15um to 45um.

5. The carbide particle reinforced Ni3Al alloy according to claim 1, characterized in that: A carbide particle reinforced Ni3Al alloy is prepared by taking element powder according to a design composition; the powder is prepared by a vacuum induction atomization method; the specific method is as follows: each metal element and a nickel-boron alloy, wherein the boron content of the nickel-boron alloy is 17% to 19%, are melted and refined in a medium frequency induction furnace, the vacuum degree is ≤10Pa, the temperature is increased to 1300°C at a heating rate of 20°C / min to 30°C / min, the temperature is increased to 1600°C to 1700°C at a heating rate of 5°C / min to 10°C / min, the temperature is kept and allowed to stand for 30min to 60min, the temperature is then controlled at 1600°C to 1650°C, the alloy solution is poured into a tundish and then into an atomizing tank through an atomizer; specifically, the diameter of the atomizing nozzle is 2mm to 6mm, the atomizing gas is high-purity nitrogen or argon; the cone angle of the retractable annular gap nozzle is 50° to 70°, and the atomizing pressure is 3MPa to 4.5MPa.

6. A use of the carbide particle reinforced Ni3Al alloy according to any one of claims 1 to 5, characterized in that: The method comprises using dried carbide particle reinforced Ni3Al alloy powder as raw material, spraying the alloy powder onto a processed substrate by supersonic flame spraying to obtain a coating; the particle size of the carbide particles in the raw material is smaller than the particle size of the raw material powder. When the coating is prepared by supersonic flame spraying, the oxygen flow rate is 735L / min to 835L / min, the kerosene flow rate is 22L / h to 24L / h; the powder feeding amount is 25g / min to 40g / min, the spraying distance is 320mm to 380mm, and the spray gun moving speed is 400mm / s to 800mm / s.

7. The use of a carbide particle reinforced Ni3Al alloy according to claim 6, characterized in that: The material of the substrate is metal material or metal ceramic material; before spraying, the roughness of the surface of the substrate is 70-85 microns.

8. The use of a carbide particle reinforced Ni3Al alloy according to claim 6, characterized in that: When the coating is prepared by supersonic flame spraying, the oxygen flow rate is 765L / min~835L / min, the kerosene flow rate is 20L / h~24L / h; the powder feeding amount is 30g / min~40g / min, the spraying distance is 350mm~360mm, and the spray gun moving speed is 500mm / s~650mm / s.

9. The use of a carbide particle reinforced Ni3Al alloy according to claim 8, characterized in that: The carbide particle reinforced Ni3Al alloy powder was pre-dried in an oven; the oven temperature was set at 60~85℃ and the drying time was 1h~3h.

10. The use of a carbide particle reinforced Ni3Al alloy according to claim 8, characterized in that: In the obtained coating, the carbide particles are uniform and fine, with an average particle size of less than 10um, preferably 1um to 5um; When the thickness of the coating is 0.02mm~0.04mm; the average hardness of the coating is 700HV~800HV, the friction coefficient is 0.4~0.5, and the wear rate is ≤3.11×10 -5 mm 3 / (N•m).

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