High-wear-resistance and high-toughness guide rail material with babbitt metal coating and preparation method and application of high-wear-resistance and high-toughness guide rail material

Abstract

The invention discloses a high-wear-resistance and high-toughness guide rail material with a babbitt metal coating and a preparation method and application thereof.The high-wear-resistance and high-toughness guide rail material with the babbitt metal coating comprises a guide rail base material and the high-wear-resistance and high-toughness coating formed on the surface of the guide rail base material, and the high-wear-resistance and high-toughness coating comprises a ferrous sulfide hard phase infiltrated by babbitt metal. As the babbitt metal has the advantages of good antifriction property, embedding property, compliance and the like, a ferrous sulfide hard phase infiltrated by the babbitt metal is formed on the surface of the guide rail base material, so that the prepared guide rail material has excellent wear resistance, corrosion resistance, thermal conductivity and self-lubricating property at the same time; the abrasion resistance, adhesion resistance and corrosion resistance of the guide rail base material can be enhanced, the friction heat capacity is reduced, the abrasion resistance of the guide rail base material is improved, and the service life is prolonged.

Description

Technical Field

[0001] The invention relates to the technical field of metal material surface treatment, and in particular to a high-wear-resistant and high-toughness guide rail material with a babbitt alloy coating, and a preparation method and application thereof. Background Art

[0002] Guide rails have a higher rated load than bearings and can bear a certain torque. They can achieve high-precision linear motion under high load conditions, so there are very high requirements for their accuracy, strength, and wear resistance.

[0003] At present, the guide rails on the market are composed of guide rails, sliders and balls. The linear motion is achieved by the rolling of balls between the guide rails and sliders. The rolling of balls between the guide rails and sliders will damage the guide rails over time, causing the guide rails to lose their moving accuracy and deform. In severe cases, the guide rails may be worn or partially fall off and fail, greatly reducing their service life. From various inspections and long-term service test data, the root cause is poor surface wear resistance and insufficient toughness of the base material. Alloy steel for guide rails is usually used in fields with high precision, high rigidity and high stability requirements, so its core is required to have good toughness, and the surface has high hardness, high strength and wear resistance.

[0004] At present, guide rails usually form an oil film on the rolling surface by adding lubricating oil and grease to reduce friction between moving parts, prevent coking and reduce wear, and extend rolling fatigue life. However, mixing different types of grease may increase the viscosity and damage system performance. When the guide rail is in a humid or corrosive gas environment for a long time, the surface is prone to rust, affecting the surface brightness of the guide rail, the chemical structure and composition of the metal material, and the pH value of the surface. In addition, friction will be generated during work. If the friction of a guide rail with poor thermal conductivity is too large, it may cause excessive temperature rise, affecting the service life of the guide rail. Summary of the invention

[0005] The purpose of the present invention is to overcome the defects of the above-mentioned prior art and to provide a high wear-resistant and high-toughness guide rail material with a babbitt alloy coating, and a preparation method and application thereof.

[0006] The present invention solves the technical problem by adopting the following technical solutions.

[0007] The invention provides a high wear-resistant and high toughness guide rail material with a babbitt alloy coating, comprising a guide rail substrate and a high wear-resistant and high toughness coating formed on the surface of the guide rail substrate, wherein the high wear-resistant and high toughness coating comprises a ferrous sulfide hard phase infiltrated by the babbitt alloy.

[0008] The present invention also provides a method for preparing the above-mentioned high wear-resistant and high toughness guide rail material with babbitt alloy coating, which comprises: preparing the high wear-resistant and high toughness coating on the surface of the guide rail substrate by ultrasonic spraying.

[0009] The present invention also provides an application of the above-mentioned high wear-resistant and high-toughness guide rail material with babbitt alloy coating in the preparation of guide rails, main shafts, gears, bearings in the field of mechanical manufacturing, engine crankshafts, camshafts in the field of rail transportation, braking systems, grinding balls, grinding discs, and chute liners in the field of mining and metallurgy.

[0010] The present invention has the following beneficial effects:

[0011] The present invention provides a high wear-resistant and high toughness guide rail material with a babbitt alloy coating, and a preparation method and application thereof. The high wear-resistant and high toughness guide rail material with a babbitt alloy coating provided by the present invention comprises a guide rail substrate and a high wear-resistant and high toughness coating formed on the surface of the guide rail substrate, and the high wear-resistant and high toughness coating comprises a ferrous sulfide hard phase infiltrated by babbitt alloy. The guide rail material having the above composition has excellent wear resistance, corrosion resistance, thermal conductivity and high toughness at the same time, can enhance the guide rail material's ability to resist abrasion, adhesion, corrosion, and friction heat, and improve the wear resistance and service life of the guide rail substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0013] Figure 1 This is a schematic diagram of the composition of a high wear-resistant and high-toughness guide rail material prepared by the method provided by the present invention. DETAILED DESCRIPTION

[0014] In order to make the purpose, technical scheme and advantages of the embodiments of the present invention clearer, the technical scheme in the embodiments of the present invention will be described clearly and completely below. If the specific conditions are not specified in the embodiments, they are carried out according to conventional conditions or conditions recommended by the manufacturer. If the manufacturer of the reagents or instruments used is not specified, they are all conventional products that can be purchased commercially.

[0015] The following is a detailed description of a high wear-resistant and high toughness guide rail material with a babbitt alloy coating provided in an embodiment of the present invention, as well as a preparation method and application thereof.

[0016] In the first aspect, an embodiment of the present invention provides a high wear-resistant and high toughness guide rail material with a babbitt alloy coating, comprising a guide rail substrate and a high wear-resistant and high toughness coating formed on the surface of the guide rail substrate, and the high wear-resistant and high toughness coating comprises a ferrous sulfide hard phase infiltrated by the babbitt alloy.

[0017] The embodiment of the present invention provides a high wear-resistant and high-toughness guide rail material with a babbitt alloy coating, and a coating of a ferrous sulfide hard phase infiltrated by babbitt alloy is formed on the surface of the guide rail substrate by using surface modification technology. The ferrous sulfide coating generally has the advantages of high hardness, significantly reducing wear and friction, having good corrosion resistance in a specific environment, and being suitable for high-temperature applications. In addition, it has the characteristics of being porous and easy to slide, so that the guide rail material prepared by it has good thermal conductivity. However, the ferrous sulfide substance of the ferrous sulfide coating is easily oxidized at room temperature. Therefore, the solution provided by the embodiment of the present invention forms a coating of a ferrous sulfide hard phase infiltrated by babbitt alloy on the surface of the guide rail substrate. After the ferrous sulfide is infiltrated and coated by the babbitt alloy, it is not easy to be oxidized. At the same time, the babbitt alloy also has the advantages of good wear reduction, embedding and compliance. After the coating of the above composition is formed on the surface of the guide rail substrate, the wear resistance, corrosion resistance, thermal conductivity and self-lubricating function of the guide rail substrate can be significantly improved, thereby improving the service life of the guide rail substrate. It can be seen that the high wear-resistant and high-toughness guide rail material prepared by the embodiment of the present invention has excellent wear resistance, corrosion resistance, impact toughness, thermal conductivity and self-lubrication, etc., which can enhance the guide rail material's anti-abrasion, anti-adhesion, corrosion resistance, and friction heat reduction capabilities, thereby improving the wear resistance and service life of the guide rail substrate.

[0018] In some optional embodiments, the high wear-resistant and high toughness coating is formed by ultrasonic spraying of iron powder, sulfur powder and babbitt alloy powder.

[0019] In some optional embodiments, the mass ratio of iron powder, sulfur powder and babbitt alloy powder is 7:4:(3.75-6.5).

[0020] In some optional embodiments, the babbitt alloy powder is a tin-based babbitt alloy powder, and the particle sizes of the iron powder, the sulfur powder and the tin-based babbitt alloy powder are all 10-30 microns.

[0021] In some optional embodiments, the chemical composition of the guide rail substrate includes, by mass percentage: C: 0.2% 1%, Si: 0.1% 0.4%, Mn: 1% 1.8%, Cr: 12% 18%, Mo: 0.5% 3%, V: 0.1% 0.45%, W: 0.1% 0.3%, Nb: 1.8% 3.6%, Ni: 0.1% 0.3%, S ≤ 0.001%, P ≤ 0.001%, Ti: ≤ 0.001%, and the rest is Fe and other unavoidable impurities.

[0022] The alloy steel used for the guide rail substrate has poor toughness and reduced fatigue life due to the number and size of carbides. Therefore, in order to solve this problem of insufficient toughness, the high wear-resistant and high-toughness guide rail material provided by the embodiment of the present invention increases the content of elements such as Cr, Mo, Nb, Ni, Mn, and V in the composition of the guide rail substrate. The addition of these elements can improve the hardenability and the size and number of precipitated carbides, thereby improving the toughness of the material. Specifically:

[0023] Chromium (Cr) is the best among them. It can not only enhance the corrosion resistance of steel, but also form hard carbides when the content is greater than 10%. With the increase of chromium content, the number of crystalline carbides increases and their morphology changes, which increases the impact toughness of the material. When the content exceeds 18%, the steel is prone to oxidation, increasing hardenability, resulting in a sharp drop in impact toughness.

[0024] Molybdenum (Mo) element can not only reduce the solidification temperature of steel, refine the γ phase, make the eutectic structure fine and evenly distributed, but also prevent grain boundary embrittlement in high temperature environment, thereby enhancing high temperature toughness. When the mass fraction of molybdenum is greater than 3%, the oxidation resistance of steel will deteriorate and the deformation resistance to hot working will decrease.

[0025] Adding niobium (Nb) in an appropriate amount can refine the grains, reduce the material's overheat sensitivity and temper brittleness, but adding more than 3.6% will generate ferrite or other brittle phases, further reducing the plasticity and toughness of the steel, while affecting the hot working properties.

[0026] The addition of nickel (Ni) can also significantly improve the organizational structure and mechanical properties of steel, and increase its toughness and plasticity. When the content is too high, the toughness of the steel decreases, and brittle fracture, corrosion or oxidation are prone to occur.

[0027] Manganese (Mn) can improve the hardenability and wear resistance of steel, and help deoxidation and desulfurization, improve the processing performance and toughness of steel. Excessive manganese content will reduce the weldability, ductility and plasticity of steel, increase brittleness, and thus affect its processing performance.

[0028] The vanadium (V) element can refine the grains and form carbides or nitrides to improve its impact toughness and wear resistance. Too high a content will change the phase structure of the steel and make it brittle.

[0029] In summary, by rationally adding the above alloy elements to the guide rail substrate, the impact toughness and overall performance of the steel matrix can be significantly improved.

[0030] In some optional implementations, the performance of the high wear-resistant and high-toughness guide rail material meets one of the following conditions:

[0031] (1) The grain size on the surface of the guide rail substrate is refined by 1.5 to 2 times, the thickness of the high wear-resistant and high-toughness coating is 2 to 3 mm, and the surface hardness of the high wear-resistant and high-toughness guide rail material can reach 60 to 70 HRC;

[0032] (2) The surface hardness of the highly wear-resistant and high-toughness guide rail material is 2 to 2.5 times higher than that of the guide rail substrate, the wear resistance is 3 to 4 times higher, and the impact toughness is 2.5 to 3 times higher;

[0033] (3) The highly wear-resistant and high-toughness guide rail material has a visual corrosion and rust spot occurrence time delayed by 3 to 4 times compared to the guide rail substrate under harsh salt spray test conditions;

[0034] (4) The friction coefficient of the highly wear-resistant and high-toughness guide rail material is 4 to 7 times lower than that of the guide rail substrate, and the wear rate is 2 to 4 times lower;

[0035] (5) The rated life of the high wear-resistant and high-toughness guide rail material is 4 to 5 times that of the guide rail base material, and the slope of the PN curve of the high wear-resistant and high-toughness guide rail material is reduced by more than 50%.

[0036] In a second aspect, an embodiment of the present invention further provides a method for preparing the above-mentioned high wear-resistant and high toughness guide rail material with a babbitt alloy coating, which comprises: preparing a high wear-resistant and high toughness coating on the surface of the guide rail substrate by an ultrasonic spraying method.

[0037] In some optional embodiments, the steps are included: loading a mixed powder of iron powder, sulfur powder and babbitt alloy powder into an ultrasonic spraying device, regulating the working gas heating temperature to 200-300°C, so that the iron powder and sulfur powder in the mixed powder react to form ferrous sulfide, which is mixed with the molten babbitt alloy and then evenly coated on the surface of the guide rail substrate through an ultrasonic nozzle, and the coating is repeated 4-5 times to form a high wear-resistant and high toughness coating with a thickness of 2-3 mm.

[0038] An embodiment of the present invention also provides a method for preparing the above-mentioned high-wear-resistant and high-toughness guide rail material with a babbitt alloy coating, which includes: mixing iron powder, sulfur powder and babbitt alloy powder and placing them in an ultrasonic spraying device, regulating the working gas to heat in the range of 200 to 300°C, and the appropriately proportioned mixed iron powder and sulfur powder undergo the following reaction at high temperature: Fe+S=FeS, the generated ferrous sulfide and the melted babbitt alloy form a layer of ferrous sulfide hard phase infiltrated by the babbitt alloy formed on the surface of the guide rail substrate, and in addition, the grains on the surface of the guide rail substrate are made finer under the action of ultrasound.

[0039] In some optional embodiments, the conditions for ultrasonic spraying are as follows: control the nozzle operating frequency to 100-200KHz, the nozzle power to 80-100W, the continuous powder spraying amount to 800-1200g / h, the spraying uniformity to <5%, and the guide air pressure to ≤0.15Mpa.

[0040] In the third aspect, an embodiment of the present invention also provides an application of the above-mentioned high wear-resistant and high toughness guide rail material with babbitt alloy coating in the preparation of guide rails, main shafts, gears, bearings in the field of mechanical manufacturing, engine crankshafts, camshafts in the field of rail transportation, braking systems, grinding balls, grinding discs, chute liners, etc. in the field of mining and metallurgy.

[0041] The present invention will be further described below in conjunction with the embodiments.

[0042] The performance test basis of the guide rail substrate and guide rail material in the following embodiments and comparative examples is as follows:

[0043] The impact toughness was measured according to the Charpy pendulum impact test method for metallic materials set out in GB / T 229-2020.

[0044] The Vickers hardness was measured according to GB / T 4340.1-2009 Metallic Materials Vickers Hardness Test Part 1: Test Method.

[0045] The depth of the hardened layer is measured according to GB / T 5617-2005 Determination of the effective hardened layer depth after induction quenching or flame quenching of steel.

[0046] According to the GB / T 6394-2017 metal average grain size determination method, the surface grains of the guide rail substrate are measured.

[0047] The wear amount was measured according to GB 10622-1989 metal material rolling contact fatigue test method.

[0048] According to GB / T 10125 artificial atmosphere corrosion test salt spray test, the time of visual corrosion rust occurrence is measured.

[0049] According to GB 10622-1989 metal material rolling contact fatigue test method, the friction coefficient and wear rate were measured.

[0050] According to JB / T 13813.7-2020 Reliability and life of rolling functional components Part 7 Rated dynamic load and fatigue life test specification for rolling linear guide pairs, the slope of the PN curve is measured, where: P is the load and N is the rated life.

[0051] Example 1

[0052] The method for preparing a guide rail material with high wear resistance and high toughness comprises the following steps:

[0053] The surface of the guide rail substrate was polished with sandpaper to remove the surface oxide scale, and the polished guide rail was placed in ethanol for ultrasonic cleaning for 15 minutes.

[0054] Select iron powder, sulfur powder and babbitt alloy powder with a mass ratio of 7:4:3.8, and micron-sized iron powder, sulfur powder and tin-based babbitt alloy powder. After mixing evenly, use ultrasonic spraying equipment, the nozzle working frequency is 150KHz, the nozzle power is 100W, the powder continuous spraying amount is 1000g / h, the spraying uniformity is <5%, and the guide air pressure is ≤0.15Mpa. Adjust the working gas heating at 300℃. The mixed powder reacts within this temperature range: Fe+S=FeS, and the babbitt alloy powder is melted and evenly coated on the surface of the guide rail with the mixed powder of ferrous sulfide through an ultrasonic nozzle. Repeat this process 4-5 times. Finally, the surface is micro-grinded to make it smooth.

[0055] The composition of the prepared high wear-resistant and high toughness guide rail material can be found in Figure 1 It can be seen that the high wear-resistant and high-toughness coating on the surface of the guide rail substrate includes a ferrous sulfide hard phase infiltrated by a tin-based babbitt alloy. The test results are as follows:

[0056] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, and the surface hardness can reach 61HRC, which is twice that of the guide rail base material. The depth of the hardened layer, that is, the thickness of the surface coating, is 2.1mm.

[0057] The surface grain of the guide rail substrate is refined by 2 times.

[0058] Under severe salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 3 times.

[0059] The surface friction coefficient of the guide rail material is reduced by 4 times, and the wear rate is reduced by 2 times compared with the guide rail base material; the wear resistance is increased by 3 times.

[0060] The rated life (L10) of the strengthened guide rail material is 4 times that of the untreated guide rail (guide rail substrate), and the slope of the PN curve is reduced by 52%.

[0061] Example 2

[0062] The difference from Example 1 is that the mass ratio of iron powder, sulfur powder and babbitt alloy powder is 7:4:6.

[0063] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, and the surface hardness can reach 68HRC, which is twice that of the guide rail base material. The depth of the hardened layer, that is, the thickness of the surface coating, is 2.7mm.

[0064] The surface grain of the guide rail substrate is refined by 2 times.

[0065] Under harsh salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 3.6 times.

[0066] The surface friction coefficient of the guide rail material is reduced by 6 times, and the wear rate is reduced by 3.5 times compared with the guide rail base material; the wear resistance is increased by 3.7 times.

[0067] The rated life (L10) of the strengthened guide rail material is 4 times that of the untreated guide rail (guide rail substrate), and the slope of the PN curve is reduced by 76%.

[0068] Example 3

[0069] The difference from Example 2 is that the continuous spraying amount of powder is 1200 g / h.

[0070] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, and the surface hardness can reach 68HRC, which is 2.5 times that of the guide rail base material. The depth of the hardened layer, that is, the thickness of the surface coating, is 3mm.

[0071] The surface grain of the guide rail substrate is refined by 2 times.

[0072] Under harsh salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 4 times.

[0073] The surface friction coefficient of the guide rail material is reduced by 7 times, and the wear rate is reduced by 4 times compared with the guide rail base material; the wear resistance is increased by 4 times.

[0074] The rated life (L10) of the strengthened guide rail material is 4 times that of the untreated guide rail (guide rail substrate), and the slope of the PN curve is reduced by 75%.

[0075] Example 4

[0076] The difference from Example 1 is that the nozzle power is 80W.

[0077] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, and the surface hardness can reach 61HRC, which is twice that of the guide rail base material. The depth of the hardened layer, that is, the thickness of the surface coating, is 2mm.

[0078] The surface grain of the guide rail substrate is refined by 2 times.

[0079] Under severe salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 3 times.

[0080] The surface friction coefficient of the guide rail material is reduced by 4 times, and the wear rate is reduced by 2 times compared with the guide rail base material; the wear resistance is increased by 3 times.

[0081] The rated life (L10) of the strengthened guide rail material is 4 times that of the untreated guide rail (guide rail substrate), and the slope of the PN curve is reduced by 50%.

[0082] Comparative Example 1

[0083] The difference from Example 2 is that the surface strengthening is performed by spraying the mixed powder using equipment without ultrasound.

[0084] The test results are as follows:

[0085] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, and the surface hardness can reach 65HRC, which is twice that of the guide rail base material. The depth of the hardened layer, that is, the thickness of the surface coating, is 2.7mm.

[0086] Under harsh salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 3.6 times.

[0087] The surface friction coefficient of the guide rail material is reduced by 6 times, and the wear rate is reduced by 2.8 times compared with the guide rail base material; the wear resistance is increased by 3.2 times.

[0088] The rated life (L10) of the strengthened guide rail material is 4 times that of the untreated guide rail (guide rail substrate), and the slope of the PN curve is reduced by 68%.

[0089] It can be seen from the above experimental results that when the mixed powder is sprayed on the surface by equipment without ultrasound for surface strengthening, there is no grain refinement effect on the surface of the base material.

[0090] Comparative Example 2

[0091] The difference from Example 1 is that the mixed powder contains only babbitt alloy powder.

[0092] The test results are as follows:

[0093] The impact toughness of the guide rail material is 2.5 times higher than that of the guide rail base material, and the surface hardness of the guide rail material can reach 30HRC.

[0094] The friction coefficient of the guide rail substrate surface is reduced by 7 times.

[0095] It can be seen from the above experimental results that when the mixed powder contains only Babbitt alloy powder, it can only improve the self-lubricating effect of the guide rail material, the surface hardness of the guide rail material is not significantly different from that of the guide rail base material, and the wear resistance and service life are not significantly improved.

[0096] Comparative Example 3

[0097] The difference from Example 1 is that the mixed powder only contains iron powder and sulfur powder.

[0098] The test results are as follows:

[0099] The impact toughness of the guide rail treated by this method is 2.5 times higher than that of the guide rail substrate, and the hardness can reach 67HRC, which is 2.4 times that of the base substrate. The depth of the hardened layer, that is, the thickness of the surface coating, is 2.8mm.

[0100] The surface grain of the base material is refined by 2 times.

[0101] Under harsh salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 4 times. The wear rate is reduced by 2.5 times compared with untreated materials; and the wear resistance is increased by 2 times.

[0102] The rated life (L10) of the strengthened guide rail material is twice that of the untreated guide rail (guide rail base material), and the slope of the PN curve is reduced by 30%.

[0103] From the above experimental results, it can be seen that when the mixed powder contains only iron powder and sulfur powder, there is no self-lubricating effect of Babbitt alloy. Although the surface hardness and wear resistance of the guide rail material are improved, the friction will damage the guide rail after a long service time, thereby affecting the service life of the guide rail.

[0104] Comparative Example 4

[0105] The difference from Example 1 is that the mass ratio of iron powder, sulfur powder and babbitt alloy powder is 7:4:2.

[0106] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, the surface hardness can reach 66HRC, and the depth of the hardened layer, that is, the thickness of the surface coating, is 1.1mm.

[0107] The surface grain of the guide rail substrate is refined by 2 times.

[0108] Under severe salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 1.4 times.

[0109] The surface friction coefficient of the guide rail material is reduced by 2 times, and the wear rate is reduced by 1 times compared with the guide rail base material; the wear resistance is increased by 1.6 times.

[0110] The rated life (L10) of the strengthened guide rail material is twice that of the untreated guide rail (guide rail substrate), and the slope of the PN curve is reduced by 28%.

[0111] From the above experimental results, it can be seen that the content of Babbitt alloy powder in the mixed powder is low, the self-lubricating effect is not significant, which affects the service life and wear resistance and fails to achieve the expected technical effect.

[0112] Comparative Example 5

[0113] The difference from Example 1 is that the mass ratio of iron powder, sulfur powder and babbitt alloy powder is 7:4:7.5.

[0114] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, the surface hardness can reach 46HRC, and the depth of the hardened layer, that is, the thickness of the surface coating, is 2mm.

[0115] The surface grain of the guide rail substrate is refined by 2 times.

[0116] Under severe salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 1.4 times.

[0117] The surface friction coefficient of the guide rail material is reduced by 6.2 times, and the wear rate is reduced by 4 times compared with the guide rail base material; the wear resistance is increased by 3 times.

[0118] The rated life (L10) of the strengthened guide rail material is three times that of the untreated guide rail (guide rail substrate), and the slope of the PN curve is reduced by 40%.

[0119] From the above experimental results, it can be seen that the content of Babbitt alloy powder in the mixed powder is relatively high, the self-lubricating effect is relatively strong, and the hard phase effect is not significant, which affects the service life and wear resistance and fails to achieve the expected technical effect.

[0120] Comparative Example 6

[0121] The difference from Example 1 is that the ultrasonic spraying temperature is 100°C.

[0122] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, the surface hardness can reach 34HRC, and the depth of the hardened layer, that is, the thickness of the surface coating, is 0.9mm.

[0123] The surface grain of the guide rail substrate is refined by 2 times.

[0124] Under severe salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 1 time.

[0125] It can be seen from the above experimental results that: the ultrasonic spraying temperature is too low, the reaction between sulfur powder and iron powder is incomplete, resulting in a decrease in the comprehensive performance of the guide rail material.

[0126] Comparative Example 7

[0127] The difference from Example 1 is that the ultrasonic spraying temperature is 450°C.

[0128] The impact toughness of the guide rail material treated by this method is 2.5 times higher than that of the guide rail base material, the surface hardness can reach 32HRC, and the depth of the hardened layer, that is, the thickness of the surface coating, is 0.8mm.

[0129] The surface grain of the guide rail substrate is refined by 2 times.

[0130] Under severe salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 1 time.

[0131] It can be seen from the above experimental results that: too high an ultrasonic spraying temperature may lead to a too fast reaction rate, and the reactants will be consumed in a short time and unable to fully react, resulting in a decrease in the comprehensive performance of the guide rail material.

[0132] From the above experimental results, it can be seen that the cooperation between Babbitt alloy powder, iron powder and sulfur powder and the appropriate parameters of ultrasonic spraying equipment under the appropriate ratio can achieve better surface strengthening effect and realize the purpose of improving wear resistance and service life.

[0133] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A high wear-resistant and high toughness guide rail material with babbitt alloy coating, characterized in that: The invention comprises a guide rail substrate and a high wear-resistant and high toughness coating formed on the surface of the guide rail substrate, wherein the high wear-resistant and high toughness coating comprises a ferrous sulfide hard phase infiltrated by a babbitt alloy.

2. The high wear-resistant and high toughness guide rail material according to claim 1, characterized in that: The high wear-resistant and high-toughness coating is formed by ultrasonic spraying of iron powder, sulfur powder and babbitt alloy powder.

3. The high wear-resistant and high toughness guide rail material according to claim 2, characterized in that: The mass ratio of iron powder, sulfur powder and babbitt alloy powder is 7:4:(3.75-6.5).

4. The high wear-resistant and high toughness guide rail material according to claim 2, characterized in that: The babbitt alloy powder is a tin-based babbitt alloy powder, and the particle sizes of the iron powder, the sulfur powder and the tin-based babbitt alloy powder are all 10-30 microns.

5. The high wear-resistant and high toughness guide rail material according to claim 1, characterized in that: The chemical composition of the guide rail substrate includes, by mass percentage: C: 0.2% 1%, Si: 0.1% 0.4%, Mn: 1% 1.8%, Cr: 12% 18%, Mo: 0.5% 3%, V: 0.1% 0.45%, W: 0.1% 0.3%, Nb: 1.8% 3.6%, Ni: 0.1% 0.3%, S≤0.001%, P≤0.001%, Ti: ≤0.001%, and the rest is Fe and other inevitable impurities.

6. The high wear-resistant and high toughness guide rail material according to any one of claims 1 to 5, characterized in that: The performance of the high wear-resistant and high-toughness guide rail material meets one of the following conditions: (1) The grain size on the surface of the guide rail substrate is refined by 1.5 to 2 times, the thickness of the high wear-resistant and high-toughness coating is 2 to 3 mm, and the surface hardness of the high wear-resistant and high-toughness guide rail material can reach 60 to 70 HRC; (2) The surface hardness of the highly wear-resistant and high-toughness guide rail material is 2 to 2.5 times higher than that of the guide rail substrate, the wear resistance is 3 to 4 times higher, and the impact toughness is 2.5 to 3 times higher; (3) The highly wear-resistant and high-toughness guide rail material has a visual corrosion rust spot occurrence time delayed by 3 to 4 times compared to the guide rail substrate under harsh salt spray test conditions; (4) The friction coefficient of the highly wear-resistant and high-toughness guide rail material is 4 to 7 times lower than that of the guide rail substrate, and the wear rate is 2 to 4 times lower; (5) The rated life of the high wear-resistant and high-toughness guide rail material is 4 to 5 times that of the guide rail base material, and the slope of the PN curve of the high wear-resistant and high-toughness guide rail material is reduced by more than 50%.

7. A method for preparing a high wear-resistant and high toughness guide rail material with a babbitt alloy coating according to any one of claims 1 to 6, characterized in that: The method comprises: preparing a high wear-resistant and high toughness coating on the surface of a guide rail substrate by adopting an ultrasonic spraying method.

8. The preparation method according to claim 7, characterized in that: The method comprises the following steps: loading a mixed powder of iron powder, sulfur powder and babbitt alloy powder into an ultrasonic spraying device, adjusting the working gas heating temperature to 200-300°C, so that the iron powder and sulfur powder in the mixed powder react to generate ferrous sulfide, and then mix with the melted babbitt alloy and evenly coat the mixture on the surface of the guide rail substrate through an ultrasonic nozzle, repeating the coating 4-5 times to form a highly wear-resistant and high-toughness coating with a thickness of 2-3 mm.

9. The preparation method according to claim 8, characterized in that: The conditions of ultrasonic spraying are as follows: control the nozzle operating frequency to 100-200KHz, the nozzle power to 80-100W, the powder continuous spraying amount to 800-1200g / h, the spraying uniformity to <5%, and the guide air pressure to ≤0.15Mpa.

10. Application of the high wear-resistant and high toughness guide rail material with babbitt alloy coating according to any one of claims 1-6 or the high wear-resistant and high toughness guide rail material with babbitt alloy coating prepared by the preparation method according to any one of claims 7-9 in the preparation of guide rails, guide rails, spindles, gears, bearings in the field of mechanical manufacturing, engine crankshafts, camshafts in the field of rail transportation, braking systems, grinding balls, grinding discs, and chute liners in the field of mining and metallurgy.

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