A high wear-resistant and high toughness guide rail material with babbitt alloy coating, preparation method and application thereof

Abstract

The present invention discloses a high-wear-resistant and high-toughness guide rail material with a babbitt alloy coating, a preparation method thereof, and an 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. Since babbitt alloy has the advantages of good friction reduction, embeddability, and compliance, a ferrous sulfide hard phase infiltrated by babbitt alloy is formed on the surface of the guide rail substrate, so that the prepared guide rail material has excellent wear resistance, corrosion resistance, thermal conductivity, and self-lubrication. It can enhance the guide rail substrate's ability to resist scratching, adhesion, corrosion, and friction heat reduction, thereby improving the wear resistance and service life of the guide rail substrate.

Description

Technical Field

[0001] The present 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, a preparation method thereof, and an 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] Currently, guide rails on the market consist of guide rails, sliders, and balls. Linear motion is achieved by the rolling of balls between the guide rails and sliders. This rolling of balls between the guide rails and sliders can damage the guide rails over time, causing them to lose precision and deform. In severe cases, this can lead to surface wear or partial detachment, significantly reducing their service life. Numerous inspections and long-term service test data indicate that the root cause is poor surface wear resistance and insufficient toughness of the base material. Guide rail alloy steel is typically used in applications requiring high precision, high rigidity, and high stability. Therefore, it is required that the core possesses excellent toughness, while the surface possesses high hardness, strength, and wear resistance.

[0004] Currently, guide rails are typically filled with lubricating oil or grease to form an oil film on the rolling surface. This reduces friction between moving parts, prevents coking, reduces wear, and prolongs rolling fatigue life. However, mixing different types of grease can increase viscosity and damage system performance. When guide rails are exposed to humidity or corrosive gases for extended periods, their surfaces are susceptible to rust, affecting the rail's surface brightness, the metal's chemical structure and composition, and its surface pH. Friction also occurs during operation. Excessive friction in guide rails with poor thermal conductivity can lead to excessive temperature rise, shortening the rail's service life. 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, a preparation method and an application thereof.

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

[0007] 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, 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 a 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 a 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 highly wear-resistant and highly tough guide rail material with a babbitt alloy coating, as well as a preparation method and application thereof. The highly wear-resistant and highly tough guide rail material with a babbitt alloy coating provided by the present invention comprises a guide rail substrate and a highly wear-resistant and highly tough coating formed on the surface of the guide rail substrate, wherein the highly wear-resistant and highly tough coating comprises a ferrous sulfide hard phase infiltrated by babbitt alloy. The guide rail material having the above composition simultaneously has excellent wear resistance, corrosion resistance, thermal conductivity, and high toughness, can enhance the guide rail material's ability to resist abrasion, adhesion, corrosion, and frictional heat reduction, 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 following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any 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 using the method provided by the present invention. DETAILED DESCRIPTION

[0014] To make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely below. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer are used. Where the manufacturer of the reagents or instruments is not specified, all are 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, a preparation method thereof, and applications thereof provided in an embodiment of the present invention.

[0016] In a 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 babbitt alloy.

[0017] The embodiment of the present invention provides a highly wear-resistant and high-toughness guide rail material with a babbitt alloy coating. A surface modification technique is used to form a coating of a ferrous sulfide hard phase impregnated with babbitt alloy on the surface of the guide rail substrate. Ferrous sulfide coatings generally have the advantages of high hardness, significantly reduced wear and friction, good corrosion resistance in specific environments, and suitability for high-temperature applications. In addition, they are porous and easy to slide, so that the guide rail material prepared therefrom has good thermal conductivity. However, the ferrous sulfide substance in 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 impregnated with babbitt alloy on the surface of the guide rail substrate. After the ferrous sulfide is impregnated and coated with babbitt alloy, it is not easily oxidized. At the same time, 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-lubrication function of the guide rail substrate can be significantly improved, thereby increasing 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-scratch, anti-adhesion, anti-corrosion, and friction heat reduction capabilities, and improve 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 base material has poor toughness and reduced fatigue life due to problems with the number and size of carbides. Therefore, 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 base material. The addition of these elements can improve the hardenability and the size and number of precipitated carbides, thereby enhancing the toughness of the material. Specifically:

[0023] Chromium (Cr) is a leading element among these, not only enhancing the corrosion resistance of steel, but also forming hard carbides when the chromium content exceeds 10%. As the chromium content increases, the number of crystalline carbides increases, and their morphology changes, increasing the material's impact toughness. When the chromium content exceeds 18%, the steel is susceptible to oxidation, increasing hardenability and causing a sharp drop in impact toughness.

[0024] Molybdenum (Mo) not only lowers the solidification temperature of steel, refines the γ phase, and makes the eutectic structure fine and evenly distributed, but also prevents grain boundary embrittlement at high temperatures, thereby enhancing high-temperature toughness. When the mass fraction of Mo exceeds 3%, the steel's oxidation resistance deteriorates and its resistance to deformation during hot working decreases.

[0025] Adding an appropriate amount of niobium (Nb) can refine the grains, reduce the material's overheating 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 performance.

[0026] The addition of nickel (Ni) can also significantly improve the structure and mechanical properties of steel, increasing its toughness and plasticity. However, when the content is too high, the toughness of the steel decreases, making it prone to brittle fracture, corrosion, or oxidation.

[0027] Manganese (Mn) can improve the hardenability and wear resistance of steel, and help deoxidation and desulfurization, thereby improving 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] Vanadium (V) can refine 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 base material, the impact toughness and overall performance of the steel matrix can be significantly improved.

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

[0031] (1) The grain size of 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 base material, 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 rust spot onset time 3 to 4 times later than that of 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 base material, and the wear rate is reduced by 2 to 4 times;

[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 following steps are included: a mixed powder of iron powder, sulfur powder and babbitt alloy powder is loaded into an ultrasonic spraying device, and the working gas heating temperature is adjusted 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 melted 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 it in an ultrasonic spraying device, regulating the working gas to heat in the range of 200-300°C, and the appropriately proportioned iron powder and sulfur powder mixture undergoes 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, which is formed on the surface of the guide rail substrate. In addition, under the action of ultrasound, the grains on the surface of the guide rail substrate are further refined.

[0039] In some optional embodiments, the conditions for ultrasonic spraying are as follows: controlling 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 a third aspect, an embodiment of the present invention further provides an application of the above-mentioned high-wear-resistant and high-toughness guide rail material with a 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 with reference to the embodiments.

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

[0043] The impact toughness was measured according to GB / T 229-2020 Metal Materials Charpy Pendulum Impact Test Method.

[0044] The Vickers hardness was measured according to GB / T 4340.1-2009 Metallic materials - Vickers hardness test - Part 1: Test method.

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

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

[0047] The wear loss was measured according to GB 10622-1989 Metal Materials 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, the rolling contact fatigue test method for metallic materials, 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] A method for preparing a high-wear-resistant and high-toughness guide rail material 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] Micron-sized iron, sulfur, and tin-based babbitt alloy powders were mixed in a mass ratio of 7:4:3.8. Ultrasonic spraying equipment was used, with a nozzle frequency of 150 kHz, a power of 100 W, and a continuous spray rate of 1000 g / h. Spray uniformity was <5%, and the guide air pressure was ≤0.15 MPa. The working air was heated at 300°C. Within this temperature range, the mixed powder reacted: Fe + S = FeS. The babbitt alloy powder melted, and the mixture, along with the ferrous sulfide powder, was evenly coated on the guide rail surface through an ultrasonic nozzle. This process was repeated 4-5 times. Finally, the surface was micro-grinded to achieve a smooth finish.

[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 consists of 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 harsh 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 base material), 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 selected to be 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 base material), 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 base material), 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 harsh 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 base material), 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 base material), and the slope of the PN curve is reduced by 68%.

[0089] From the above experimental results, it can be seen that when the mixed powder is sprayed on the surface of the substrate using equipment without ultrasound for surface strengthening, there is no grain refinement effect on the surface of the substrate.

[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 base material surface is reduced by 7 times.

[0095] From the above experimental results, it can be seen 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 base material, and the hardness can reach 67HRC, which is 2.4 times that of the base material. 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 onset of visual corrosion rust can be delayed by 4 times. The wear rate is reduced by 2.5 times compared to 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 period of service, 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 harsh 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 base material), 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 harsh 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 base material), 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 harsh salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 1 time.

[0125] From the above experimental results, it can be seen 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 harsh salt spray test conditions, the time for visual corrosion rust to occur can be delayed by 1 time.

[0131] From the above experimental results, it can be seen that if the ultrasonic spraying temperature is too high, the reaction rate may be too fast, the reactants will be consumed in a short time, and they will not be able 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 use of ultrasonic spraying equipment with appropriate parameters in a suitable ratio can achieve a better surface strengthening effect and realize the purpose of improving wear resistance and service life.

[0133] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A high wear-resistant and high toughness guide rail material with a 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, and the high wear-resistant and high toughness coating is formed by ultrasonic spraying of iron powder, sulfur powder and babbitt alloy powder, wherein the mass ratio of the iron powder, sulfur powder and babbitt alloy powder is 7:4:(3.75-6.5), the babbitt alloy powder is a tin-based babbitt alloy powder, and the chemical composition of the guide rail substrate is as follows: The total content of aluminum alloy is 2.57777%, which is 2.13777% and 2.71777% respectively. It includes: 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.

2. The high wear-resistant and high toughness guide rail material according to claim 1, characterized in that: The particle sizes of the iron powder, sulfur powder and tin-based babbitt alloy powder are all 10-30 microns.

3. The high wear-resistant and high toughness guide rail material according to claim 1 or 2, 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 base material, 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 onset time 3 to 4 times later than that of the guide rail substrate under harsh salt spray test conditions; (4) The high wear-resistant and high-toughness guide rail material has a friction coefficient 4 to 7 times lower than that of the guide rail base material, and a wear rate 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%.

4. 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 3, characterized in that: The method comprises the following steps: loading a mixed powder of iron powder, sulfur powder and babbitt alloy powder into ultrasonic spraying equipment, regulating 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 mixing with the melted babbitt alloy to be evenly coated on the surface of the guide rail substrate through an ultrasonic nozzle, repeating the coating 4-5 times to form a high-wear-resistant and high-toughness coating with a thickness of 2-3 mm.

5. The preparation method according to claim 4, characterized in that The conditions for 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.

6. Application of the high wear-resistant and high toughness guide rail material with babbitt alloy coating according to any one of claims 1 to 3 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 4 to 5 in guide rails, main shafts, gears and bearings in the field of mechanical manufacturing.

7. Application of the high wear-resistant and high toughness guide rail material with babbitt alloy coating according to any one of claims 1 to 3 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 4 to 5 in engine crankshafts and camshafts in the field of rail transportation.

8. Application of the high wear-resistant and high toughness guide rail material with babbitt alloy coating according to any one of claims 1 to 3 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 4 to 5 in grinding balls, grinding discs, and chute liners in braking systems, mining and metallurgy fields.

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