Method for producing self-fluxing alloy coating film, self-fluxing alloy coating film, member, and powder material

Abstract

The present invention is a method for producing a self-fluxing alloy coating film, which is characterized by comprising: a step in which a powder material obtained by mixing a first powder, a second powder, and a third powder is sprayed onto a base material, and a sprayed coating film is formed on the base material; and a step for melting the sprayed coating film to form a self-fluxing alloy coating film.

Description

Technical Field

[0001] The present invention relates to a method for producing a self-fluxing alloy film, and a self-fluxing alloy film, a component, and a powder material formed using the production method. Background Art

[0002] Continuous casting involves pouring molten steel into a water-cooled copper mold, pulling out the cast piece while it solidifies only on the surface, and supporting it with rollers while cooling it with spray water to allow it to slowly solidify. However, the continuous casting rollers used in this continuous casting equipment operate in a harsh environment with repeated rapid heating and cooling, and are susceptible to wear and damage during the transport of the cast piece. Therefore, these continuous casting rollers require wear resistance.

[0003] For example, Patent Document 1 proposes a breakage-resistant and wear-resistant roll for continuous casting, which is formed by spraying and overlaying a Ni-based or Co-based self-fluxing alloy on the main body surface of a stainless steel roll and then performing a melt heat treatment.

[0004] Patent Document 2 proposes a continuous casting roll having a spray coating layer containing a Ni-based or Co-based self-fluxing alloy and carbides such as tungsten carbide. Prior art literature Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. S57-203765 Patent Document 2: Japanese Patent Application Laid-Open No. 2006-263807 Summary of the Invention -Problems to be solved by the invention-

[0006] The breakage-resistant and wear-resistant roll for continuous casting proposed in Patent Document 1 has a spray deposit layer of a Ni-based or Co-based self-fluxing alloy type sprayed metal on the surface of the main body of a stainless steel roll, but the wear resistance is insufficient.

[0007] Patent Document 2 describes that by adding carbides such as tungsten carbide to a Ni-based or Co-based self-fluxing alloy, a spray coating layer composed of a self-fluxing alloy with excellent wear resistance can be formed. Furthermore, it describes that by significantly reducing the carbon content in the self-fluxing alloy, the spray coating layer is prevented from becoming hard and brittle, and the formation of a carburized layer during fusing treatment is suppressed, thereby achieving a spray coating layer with a low likelihood of peeling.

[0008] However, the results of research conducted by the present inventors have shown that, as disclosed in Patent Document 2, even a spray coating layer containing a Ni-based or Co-based self-fluxing alloy and carbides such as tungsten carbide has insufficient thermal shock resistance.

[0009] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a method for forming a self-fluxing alloy film having both wear resistance and thermal shock resistance on a substrate. -Solutions to solve the problem-

[0010] The method for producing a self-fluxing alloy film of the present invention is characterized by performing the following steps (a) and (b). (a) spraying a powder material obtained by mixing a first powder, a second powder, and a third powder onto a substrate to form a spray coating on the substrate; (b) a step of melting the sprayed film to form a self-fluxing alloy film.

[0011] Furthermore, the method for producing a self-fluxing alloy film of the present invention has the following features (1) and (2). (1) The first powder is one or more self-fluxing alloys selected from Ni-based self-fluxing alloys and Co-based self-fluxing alloys, and the self-fluxing alloys contain 0.8 to 4.5 mass % of B and 1.5 to 5.0 mass % of Si; the second powder is one or more selected from carbide ceramics and carbide metal ceramics; and the third powder is one or more selected from Cr, Mo, Fe, Ni, Co, and alloys with any one of them as the main component, but for alloys with Ni as the main component and alloys with Co as the main component, the Ni-based self-fluxing alloys and Co-based self-fluxing alloys defined by the first powder are excluded. (2) In the third powder, when the element with the largest content on a mass basis is Cr, Fe, Ni or Co, the powder material contains 45 to 65 mass% of the first powder, 5 to 35 mass% of the second powder, and 5 to 50 mass% of the third powder. In addition, in the third powder, when the element with the largest content on a mass basis is Mo, the powder material contains 70 to 85 mass% of the first powder, 5 to 25 mass% of the second powder, and 5 to 25 mass% of the third powder.

[0012] Furthermore, the following (3) to (5) can be cited as preferable conditions for the method of producing the self-fluxing alloy film of the present invention. (3) The first powder contains 2.5 to 4.0 mass % of B and 3.0 to 5.0 mass % of Si. (4) The second powder is tungsten carbide cermet, and the total content of W and C is 70% by mass or more. (5) The third powder contains 10 to 30 mass% of Cr or 5 to 20 mass% of Mo.

[0013] In addition, as the applicable objects of the method for producing the self-fluxing alloy film of the present invention, the following (6) to (10) can be listed. (6) A self-fluxing alloy film formed using the manufacturing methods of (1) to (5) above. (7) A component of an ironmaking facility having a self-fluxing alloy film formed on a substrate using the manufacturing method of (1) to (5) above. (8) A component of pig iron making equipment, steel making equipment, or non-ferrous metal refining equipment having a self-fluxing alloy film formed on a substrate using the manufacturing method of (1) to (5) above. (9) A component of equipment for hot rolling of steel or non-ferrous metal, wherein a self-fluxing alloy film is formed on a substrate using the manufacturing method of (1) to (5) above. (10) A component of a continuous casting apparatus in which a self-fluxing alloy film is formed on a substrate using the manufacturing method of (1) to (5) above.

[0014] In addition, the powder material of the present invention is a powder material obtained by mixing a first powder, a second powder, and a third powder, and has the following characteristics (11) and (12). (11) The first powder is one or more self-fluxing alloys selected from Ni-based self-fluxing alloys and Co-based self-fluxing alloys, and the self-fluxing alloys contain 0.8 to 4.5 mass% of B and 1.5 to 5.0 mass% of Si; the second powder is one or more selected from carbide ceramics and carbide metal ceramics; and the third powder is one or more selected from Cr, Mo, Fe, Ni, Co, and alloys with any one of them as the main component, but for alloys with Ni as the main component and alloys with Co as the main component, the Ni-based self-fluxing alloys and Co-based self-fluxing alloys defined by the first powder are excluded. (12) In the third powder, when the element with the largest content on a mass basis is Cr, Fe, Ni or Co, the powder material contains 45 to 65 mass% of the first powder, 5 to 35 mass% of the second powder, and 5 to 50 mass% of the third powder. In addition, in the third powder, when the element with the largest content on a mass basis is Mo, the powder material contains 70 to 85 mass% of the first powder, 5 to 25 mass% of the second powder, and 5 to 25 mass% of the third powder. -Effects of the Invention-

[0015] According to the present invention, a self-fluxing alloy film having both wear resistance and thermal shock resistance can be formed on a substrate. DETAILED DESCRIPTION

[0016] Hereinafter, one embodiment of the method for producing a self-fluxing alloy film and a powder material according to the present invention will be described.

[0017] The method for producing a self-fluxing alloy film according to the present embodiment includes the following steps (a) and (b). (a) spraying a powder material obtained by mixing a first powder, a second powder, and a third powder onto a substrate to form a spray film on the substrate; (b) A step of melting the sprayed film to form a self-fluxing alloy film.

[0018] In step (a), a powder material obtained by mixing the first powder, the second powder, and the third powder is sprayed onto the base material to form a spray film on the base material.

[0019] The substrate can be, for example, a metal substrate, but is not particularly limited and may be any substrate. Alternatively, a stainless steel substrate can be used as the metal substrate. Furthermore, the substrate in the present invention may include a substrate having a coating applied to the surface. Examples of such coatings include iron-chromium solidified deposited layers.

[0020] The powder material is a mixture of a first powder, a second powder, and a third powder, and is used for self-fluxing alloy spraying. The powder material may contain other powder components in addition to the first, second, and third powders. The total amount of the first, second, and third powders is preferably 80% by mass or greater of the total powder, more preferably 90% by mass or greater, and even more preferably 95% by mass or greater. It is particularly preferred that the powder material be composed solely of the first, second, and third powders, and unavoidable impurities.

[0021] The first powder is one or more self-fluxing alloys selected from Ni-based and Co-based self-fluxing alloys, containing 0.8-4.5% by mass of boron and 1.5-5.0% by mass of silicon. If the boron and silicon contents fall within these ranges, the alloy's melting temperature decreases, imparting self-fluxing properties and improving the operability of the melt treatment in step (b). More preferably, the self-fluxing alloy contains 2.5-4.0% by mass of boron and 3.0-5.0% by mass of silicon. If the boron and silicon contents fall within these ranges, the aforementioned effects are more readily achieved.

[0022] The first powder is not particularly limited as long as it meets the above requirements. For example, it can be selected from one, two, three, four, five, six, seven, eight, or nine Ni-based self-fluxing alloys shown in Table 1 below, or one or two Co-based self-fluxing alloys. Such first powders have the effect of particularly improving the thermal shock resistance of the self-fluxing alloy film. It should be noted that where "the following" is indicated in Table 1, the element in question need not be present.

[0023] [Table 1]

[0024] The second powder is one or more selected from carbide ceramics and carbide cermets. As carbide ceramics, for example, tungsten carbide (WC), chromium carbide (Cr3C2 etc.), niobium carbide (NbC) etc. can be listed. As carbide cermets, a composite formed by the composite of metals in these carbide ceramics can be listed. Such a second powder has the effect of improving the wear resistance of the self-fluxing alloy film. The second powder is particularly preferably tungsten carbide cermets. Tungsten carbide cermets can appropriately use the cermets commonly used in the technical field. For example, tungsten carbide cermets can use WC-Co, WC-Co-Cr or WC-Ni etc. In addition, the tungsten carbide cermet is preferably more than 70 mass % relative to the whole tungsten carbide cermet in terms of the content of W and the content of C. If the content of W and the content of C add up to more than 70 mass %, the wear resistance of the self-fluxing alloy film improves.

[0025] The third powder is one or more selected from Cr, Mo, Fe, Ni, Co, and alloys with any of these as the main component. However, for alloys with Ni as the main component (hereinafter also referred to as "Ni-based alloys") and alloys with Co as the main component (hereinafter also referred to as "Co-based alloys"), they are materials other than the Ni-based self-fluxing alloys and Co-based self-fluxing alloys defined by the first powder. It should be noted that in this specification, the main component refers to the component with the highest content ratio among all the components based on mass. In addition, the main component is preferably 40% by mass or more of the total components, more preferably 50% by mass or more, and even more preferably 60% by mass or more. As Ni-based alloys that can be used as the third powder, for example, it can be selected from MONEL K500, MONEL 400, HASTELLOY B, HASTELLOY C276, HASTELLOY C22, INCONEL 600, INCONEL 625, INCOLOY 800, and INCOLOY 825. In addition, Co-based alloys that can be used as the third powder include, for example, STELLITE 6, STELLITE 12, STELLITE 21, STELLITE 31, TRIBALOY T-400, and TRIBALOY T-800. In addition, Fe-based alloys that can be used as the third powder include, for example, SUS316L, SUS304, SUS310S, SUS430, SUS420J2, and S45C. In addition, Mo-based alloys that can be used as the third powder include, for example, MoSi2 and Mo-Ti-Zr-C (TZM alloy). Furthermore, the third powder preferably contains 10-30% by mass of Cr or 5-20% by mass of Mo. As a result, the Cr or Mo in the third powder combines with the B contained in the first powder to form an intermetallic compound, thereby improving the wear resistance of the self-fluxing alloy film. Furthermore, the Cr, Mo, Fe, Ni, or Co used as the third powder may contain one or more other metal components as impurities in addition to these metal components.

[0026] When the element with the highest mass content in the third powder is Cr, Fe, Ni, or Co, the powder material contains 45-65 mass% of the first powder, 5-35 mass% of the second powder, and 5-50 mass% of the third powder. If the first powder content is less than 45 mass%, the meltability of the self-fluxing alloy spray film is insufficient, and the quality of the melted self-fluxing alloy film may be poor. On the other hand, if the first powder content exceeds 65 mass%, the self-fluxing alloy film becomes hard and brittle, and the film's thermal shock resistance is insufficient. Furthermore, if the second powder content is less than 5 mass%, the self-fluxing alloy film's wear resistance is insufficient. On the other hand, if the second powder content exceeds 35 mass%, the self-fluxing alloy film becomes hard and brittle, and the film's thermal shock resistance is insufficient. Furthermore, if the third powder content is less than 5 mass%, the binder cannot fully function, and the thermal shock resistance of the self-fluxing alloy film is insufficient. On the other hand, if the third powder content exceeds 50 mass%, the wear resistance of the self-fluxing alloy film is insufficient. Note that when each powder contains multiple materials, the total of these materials is defined as the content of each material. For example, although INCONEL 625 and STELLITE 21 are both classified as third powder, if the powder material contains both, their total content only needs to be 5-50% by mass of the total powder material.

[0027] When the element with the highest mass content in the third powder is Mo, the powder material contains 70-85% by mass of the first powder, 5-25% by mass of the second powder, and 5-25% by mass of the third powder. If the first powder content is less than 70% by mass, the meltability of the self-fluxing alloy spray coating may be insufficient, and the quality of the self-fluxing alloy coating after melting may be poor. On the other hand, if the first powder content exceeds 85% by mass, the self-fluxing alloy coating becomes hard and brittle, and the thermal shock resistance of the coating may be insufficient. Furthermore, if the second powder content is less than 5% by mass, the wear resistance of the self-fluxing alloy coating may be insufficient. On the other hand, if the second powder content exceeds 25% by mass, the self-fluxing alloy coating may become hard and brittle, and the thermal shock resistance of the coating may be insufficient. Furthermore, if the third powder content is less than 5% by mass, the binder effect may not be fully exerted, and the thermal shock resistance of the self-fluxing alloy coating may be insufficient. On the other hand, if the third powder content exceeds 25% by mass, the wear resistance of the self-fluxing alloy coating may be insufficient. It should be noted that when each powder contains multiple materials, the total of these materials is defined as the content of each material. For example, although Mo and MoSi2 are both classified as the third powder, when the powder material contains both, it is sufficient that they account for 5 to 25 mass % of the entire powder material.

[0028] The spraying in step (a) can be performed by any spraying method, such as powder flame spraying, plasma spraying, and preferably atmospheric plasma spraying.

[0029] In step (a), the shape and size of the substrate are not particularly limited and may be any shape. In step (a), the film thickness of the spray coating formed on the substrate is, for example, 500 to 5000 μm.

[0030] In step (b), the sprayed coating formed in step (a) is melted (remelted) to form a self-fluxing alloy coating.

[0031] In step (a), the sprayed film formed on the substrate is melt-treated. The melt treatment is not particularly limited and can be carried out under conditions commonly used in the field of self-fluxing alloy spraying, for example, the temperature of the film is raised to 950°C to 1200°C in the air or in a non-oxidizing atmosphere for melting. By such a melt treatment, the pores in the sprayed film can be reduced, the sprayed film can be densified, and a diffusion layer can be formed between the substrate and the sprayed film, thereby forming a self-fluxing alloy film with high adhesion. It should be noted that the melting treatment temperatures of the Ni-based self-fluxing alloy and the Co-based self-fluxing alloy defined by the first powder are approximately the same and can be selected according to the use environment of the film.

[0032] In the self-fluxing alloy film formed in step (b), the thickness of the diffusion layer formed between the substrate and the sprayed film is, for example, 50 to 500 μm. In addition, the self-fluxing alloy film contains a substrate component in addition to the components of the first to third powders. Such a substrate component is preferably 10% by mass or less. That is, the self-fluxing alloy film formed in step (b) contains components derived from the first to third powders and components derived from the substrate. The total amount of the components derived from the first to third powders and the components derived from the substrate is preferably 80% by mass or more of the entire film, more preferably 90% by mass or more, further preferably 95% by mass or more, and particularly preferably consists only of components derived from the first to third powders, components derived from the substrate, and unavoidable impurities. The types of unavoidable impurities are not particularly limited, such as impurities mixed in from the outside during steps (a) and (b).

[0033] The wear amount of the self-fluxing alloy film formed in step (b) is, for example, 0 to 200 mg / 2000 times as measured by the Suga wear test described below. If the wear amount of the self-fluxing alloy film exceeds 200 mg / 2000 times, the wear resistance of the film is insufficient. Furthermore, the wear amount of the self-fluxing alloy film formed in step (b) is preferably 0 to 100 mg / 2000 times, and more preferably 0 to 50 mg / 2000 times as measured by the Suga wear test.

[0034] The thermal shock resistance of the self-fluxing alloy film formed in step (b) is evaluated as ○ or △ in the thermal shock resistance test described below. If the thermal shock resistance of the self-fluxing alloy film is evaluated as ×, the thermal shock resistance of the film is insufficient.

[0035] An example of a method for manufacturing a self-fluxing alloy film according to the present embodiment is described below. First, the first powder, the second powder, and the third powder are weighed separately and transferred to a container, and the powders are mixed to prepare a powder material. Then, the surface of the substrate is sprayed with the prepared powder material to form a spray film on the substrate. For example, in the case of atmospheric plasma spraying, a voltage is applied between the cathode and the anode to generate a DC arc. Then, a working gas such as argon is supplied to the DC arc to ionize the working gas and generate a high-temperature, high-speed plasma jet. Then, the powder material is supplied to the generated plasma jet with argon gas or the like and blown toward the substrate to form a spray film (step (a)). Finally, the spray film formed on the substrate is heated with a flame of about 3000°C in the atmosphere, for example, to raise the film temperature to about 1000°C for melting to form a self-fluxing alloy film (step (b)). In this way, a self-fluxing alloy film having both wear resistance and thermal shock resistance can be manufactured. However, the method for producing the self-fluxing alloy film according to the present embodiment is not limited to the above-mentioned example. [Example]

[0036] Hereinafter, examples and comparative examples to which the present invention is applied will be described. These examples are merely examples of the present invention and do not limit the scope of the invention.

[0037] [First Powder] As the first powder, a powder of a Ni-based self-fluxing alloy (hereinafter also referred to as "Ni-3B-4.4Si") containing 3.05 mass% of B, 0.02 mass% of C, 4.43 mass% of Si, with the remainder consisting of Ni (i.e., Ni is 92.50 mass%) was prepared (manufactured by FUKUDA METAL FOIL & POWDER CO., LTD.).

[0038] [Second powder] As the second powder, a tungsten carbide cermet (hereinafter also referred to as "WC-12Co") powder (manufactured by Sumitomo Metal Mining Co., Ltd.) containing 5.40 mass % of C, 11.70 mass % of Co, and the remainder of W (ie, 82.90 mass % of W) was prepared.

[0039] [Third Powder] As the third powder, a powder of a Ni-based alloy (hereinafter also referred to as "INCONEL 625") containing 0.46 mass% Si, 21.20 mass% Cr, 0.46 mass% Fe, 3.57 mass% Nb, 9.10 mass% Mo, with the balance being Ni (i.e., 65.21 mass% Ni) was prepared (manufactured by Hoganas Co., Ltd.). Also prepared as the third powder was a powder of an Fe-based alloy (hereinafter also referred to as "SUS316L") containing 0.02 mass% C, 0.91 mass% Si, 17.27 mass% Cr, 12.75 mass% Ni, with the balance being Fe (i.e., 69.05 mass% Fe) (manufactured by Sanyo Special Steel Co., Ltd.). A third powder was prepared using a Co-based alloy (hereinafter also referred to as "STELLITE 21") containing 0.26 mass% C, 1.25 mass% Si, 26.92 mass% Cr, 1.32 mass% Fe, 3.02 mass% Ni, and 6.05 mass% Mo, with the remainder being Co (i.e., 61.18 mass% Co). Furthermore, a third powder was prepared using a Mo powder (manufactured by POWREX CO., LTD.) containing 0.29 mass% C, 0.03 mass% Fe, and the remainder being Mo (i.e., 99.68 mass% Mo).

[0040] The chemical compositions of the first powder, the second powder, and the third powder prepared in this example are shown in Table 2 below.

[0041] [Table 2]

[0042] [Example 1] A powder material was prepared containing 60% by mass of a first powder (Ni-3B-4.4Si (Ni-based self-fluxing alloy), 10% by mass of a second powder (WC-12Co (WC cermet), and 30% by mass of a third powder (INCONEL 625). This powder material was then used to form a spray coating on a 50 mm x 50 mm x 30 mm thick S45C substrate by atmospheric plasma spraying under the following conditions. The spray coating was then heated to approximately 1000°C and melted to form a self-fluxing alloy coating, producing the test piece of Example 1. Current value: 400A Argon flow rate: 36 NLPM

[0043] [Example 2] The test piece of Example 2 was prepared by the same method as Example 1, except that a powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 15 mass% of the second powder WC-12Co (WC cermet), and 25 mass% of the third powder INCONEL 625 was used in the entire powder material.

[0044] [Example 3] A test piece of Example 3 was prepared using the same method as Example 1, except that the powder material contained 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 20 mass% of the second powder WC-12Co (WC cermet), and 20 mass% of the third powder INCONEL 625.

[0045] [Example 4] A test piece of Example 4 was produced by the same method as in Example 1, except that a powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 25 mass% of the second powder WC-12Co (WC cermet), and 15 mass% of the third powder INCONEL 625 was used in the entire powder material.

[0046] [Example 5] A test piece of Example 5 was prepared using the same method as Example 1, except that the powder material contained 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 30 mass% of the second powder WC-12Co (WC cermet), and 10 mass% of the third powder INCONEL 625.

[0047] [Example 6] The test piece of Example 6 was produced by the same method as in Example 1, except that a powder material containing 50 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 20 mass% of the second powder WC-12Co (WC cermet), and 30 mass% of the third powder INCONEL 625 was used in the entire powder material.

[0048] [Example 7] A test piece of Example 7 was produced by the same method as in Example 1, except that a powder material containing 50 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 25 mass% of the second powder WC-12Co (WC cermet), and 25 mass% of the third powder INCONEL 625 was used in the entire powder material.

[0049] [Example 8] A test piece of Example 8 was produced by the same method as in Example 1, except that a powder material containing 50 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 30 mass% of the second powder WC-12Co (WC cermet), and 20 mass% of the third powder INCONEL 625 was used in the entire powder material.

[0050] [Example 9] A powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 10 mass% of the second powder WC-12Co (WC metal ceramic), and 30 mass% of the third powder SUS316L in the entire powder material was used. Except for this, the test piece of Example 9 was prepared using the same method as Example 1.

[0051] [Example 10] A powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 20 mass% of the second powder WC-12Co (WC metal ceramic), and 20 mass% of the third powder SUS316L in the entire powder material was used. Except for this, the test piece of Example 1 was prepared using the same method as Example 1.

[0052] [Example 11] A powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 30 mass% of the second powder WC-12Co (WC metal ceramic), and 10 mass% of the third powder SUS316L in the entire powder material was used. Except for this, the test piece of Example 11 was prepared using the same method as Example 1.

[0053] [Example 12] A test piece of Example 12 was produced by the same method as in Example 1, except that a powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 10 mass% of the second powder WC-12Co (WC cermet), and 30 mass% of the third powder STELLITE 21 was used in the entire powder material.

[0054] [Example 13] A test piece of Example 13 was produced by the same method as in Example 1, except that a powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 20 mass% of the second powder WC-12Co (WC cermet), and 20 mass% of the third powder STELLITE 21 was used in the entire powder material.

[0055] [Example 14] A test piece of Example 14 was produced by the same method as in Example 1, except that a powder material containing 60 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 30 mass% of the second powder WC-12Co (WC cermet), and 10 mass% of the third powder STELLITE 21 was used in the entire powder material.

[0056] [Example 15] A powder material containing 80 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 5 mass% of the second powder WC-12Co (WC metal ceramic), and 15 mass% of the third powder Mo in the entire powder material was used. Except for this, the test piece of Example 15 was prepared using the same method as Example 1.

[0057] [Example 16] A powder material containing 80 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 10 mass% of the second powder WC-12Co (WC metal ceramic), and 10 mass% of the third powder Mo in the entire powder material was used. Except for this, the test piece of Example 16 was prepared using the same method as Example 1.

[0058] [Example 17] A powder material containing 75 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 15 mass% of the second powder WC-12Co (WC metal ceramic), and 10 mass% of the third powder Mo in the entire powder material was used. Except for this, the test piece of Example 17 was prepared using the same method as Example 1.

[0059] [Comparative Example 1] A test piece of Comparative Example 1 was prepared by the same method as in Example 1 except that a powder material containing 100 mass % of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy) was used in the entire powder material.

[0060] [Comparative Example 2] A test piece of Comparative Example 2 was prepared by the same method as Example 1 except that a powder material containing 65 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy) and 35 mass% of the second powder WC-12Co (WC cermet) was used in the entire powder material.

[0061] [Comparative Example 3] A test piece of Comparative Example 3 was prepared using the same method as Example 1, except that the powder material contained 70 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 10 mass% of the second powder WC-12Co (WC cermet), and 20 mass% of the third powder INCONEL 625.

[0062] [Comparative Example 4] A test piece of Comparative Example 4 was prepared using the same method as Example 1, except that the powder material contained 70 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 15 mass% of the second powder WC-12Co (WC cermet), and 15 mass% of the third powder INCONEL 625.

[0063] [Comparative Example 5] A test piece of Comparative Example 5 was prepared using the same method as Example 1, except that the powder material contained 70 mass% of the first powder Ni-3B-4.4Si (Ni-based self-fluxing alloy), 20 mass% of the second powder WC-12Co (WC cermet), and 10 mass% of the third powder INCONEL 625.

[0064] As described below, the test pieces obtained in Examples 1 to 17 and Comparative Examples 1 to 5 were subjected to a hardness test (Hv) of the self-fluxing alloy film, a Suga wear test, and a thermal shock resistance test.

[0065] [Hardness test] In the hardness test of the self-fluxing alloy film, a micro Vickers hardness tester was used, and ten-point measurements were performed with a load of 300 gf, and the average value was calculated.

[0066] [Suga-type wear test] The Suga-type wear test of the self-fluxing alloy film was conducted with a load of 3.25 kg·f, a rotation speed of 60 rpm, and 2000 reciprocating strokes using SiC#320 test paper. The wear loss was evaluated using the following criteria based on the measured wear loss. ◎: less than 50 mg. ○: 50 mg or more and less than 100 mg. △: 100 mg or more and less than 200 mg.

[0067] [Thermal shock resistance test] In the thermal shock resistance test of self-fluxing alloy films, a test piece is heated with a high-temperature flame to a surface temperature of approximately 100-150°C, followed by water cooling. This operation is repeated as one set to determine whether the film peels off. Thermal shock resistance is evaluated using the following indicators. ○: Peeling occurred after the fourth time, or no peeling occurred. △: Peeling occurred for the third time. ×: Peeling occurred for the first or second time.

[0068] Table 3 is a summary table of the results of the above-mentioned tests performed on the test pieces of Examples 1 to 17 and Comparative Examples 1 to 5.

[0069] [Table 3]

[0070] It should be noted that observation of the test pieces after the thermal shock test, as the number of tests increased, showed that multiple cracks initially formed on the film surface. As the number of tests increased, these cracks combined to form large cracks, resulting in film delamination. Therefore, it is believed that the combination of multiple cracks into large cracks is one of the main causes of film delamination.

[0071] The results in Table 3 confirm that in Examples 1 to 14, the wear loss evaluation was consistently △ or higher, and the thermal shock resistance was consistently △ or higher. Therefore, it can be seen that the self-fluxing alloy films of Examples 1 to 14 possess both wear resistance and thermal shock resistance. Specifically, it can be seen that, when the element with the highest content in the third powder is Fe, Ni, or Co, a spray coating formed using a powder material containing 45-65% by mass of the first powder, 5-35% by mass of the second powder, and 5-50% by mass of the third powder, followed by a melt treatment, can form a self-fluxing alloy film possessing both wear resistance and thermal shock resistance. It should be noted that, because rigorous evaluations were performed in this example, although some of the Examples and Comparative Examples included △ in the wear loss evaluation and thermal shock resistance evaluation, the △ evaluations were generally good.

[0072] The results in Table 3 confirm that in Examples 15 to 17, the wear loss evaluation was △ or higher, and the thermal shock resistance evaluation was ○. Therefore, it can be seen that the self-fluxing alloy films of Examples 15 to 17 possess both wear resistance and thermal shock resistance. Specifically, it can be seen that, when the element with the highest content in the third powder is Mo, a spray coating formed using a powder material containing 70-85% by mass of the first powder, 5-25% by mass of the second powder, and 5-25% by mass of the third powder, followed by a melt treatment, can form a self-fluxing alloy film possessing both wear resistance and thermal shock resistance.

[0073] These results confirm that when INCONEL 625 is used as the third powder as shown in Examples 1 to 8, when SUS316L is used as the third powder as shown in Examples 9 to 11, when STELLITE 21 is used as the third powder as shown in Examples 12 to 14, and when Mo is used as the third powder as shown in Examples 15 to 17, a self-fluxing alloy film having both wear resistance and thermal shock resistance can be formed.

[0074] On the other hand, the results in Table 3 confirm that, as in Comparative Example 1, the powder material consisting solely of the first powder received a negative rating for thermal shock resistance. Furthermore, the results in Table 3 confirm that, as in Comparative Example 2, the powder material lacked the third powder and contained only appropriate amounts of the first and second powders, while the wear rate was rated as ◎ and the thermal shock resistance was rated as negative. Furthermore, the results in Table 3 confirm that, as in Comparative Examples 3 to 5, the powder material contained 70% by mass of the first powder, while the thermal shock resistance was rated as negative. These results demonstrate that in order to form a self-fluxing alloy film exhibiting both wear resistance and thermal shock resistance, a powder material containing the first, second, and third powders in appropriately proportioned proportions is necessary.

[0075] The above results confirm that a method for manufacturing a self-fluxing alloy film comprises the steps of spraying a powder material obtained by mixing appropriate amounts of a first powder, a second powder, and a third powder onto a substrate to form a sprayed film; and melting the sprayed film to form a self-fluxing alloy film. A self-fluxing alloy film having both wear resistance and thermal shock resistance can be formed. -Industrial Applicability-

[0076] The method for producing a self-fluxing alloy film according to the present invention can form a self-fluxing alloy film on a substrate that exhibits both wear resistance and thermal shock resistance. Therefore, it can be widely applied to industries such as steel and non-ferrous metals. In particular, it can be applied to equipment for ironmaking, pig iron production, steelmaking, non-ferrous metal refining, hot rolling equipment for steel and non-ferrous metals, and continuous casting.

Claims

1. A method for producing a self-fluxing alloy film, wherein: The method has: a step of spraying a powder material obtained by mixing a first powder, a second powder, and a third powder onto a substrate to form a spray coating on the substrate; and The process of melting the sprayed film to form a self-fluxing alloy film; The first powder is one or more self-fluxing alloys selected from Ni-based self-fluxing alloys and Co-based self-fluxing alloys, wherein the self-fluxing alloy contains 0.8-4.5 mass % of B and 1.5-5.0 mass % of Si. The second powder is one or more selected from carbide ceramics and carbide cermets, The third powder is one or more selected from Cr, Mo, Fe, Ni, Co, and alloys containing any of these as a main component, but for alloys containing Ni as a main component and alloys containing Co as a main component, the Ni-based self-fluxing alloy and the Co-based self-fluxing alloy defined by the first powder are excluded. In the third powder, when the element with the largest content on a mass basis is Cr, Fe, Ni or Co, The powder material contains: 45-65% by mass of the first powder, 5 to 35% by mass of the second powder, and 5 to 50% by mass of the third powder, In the third powder, when the element with the largest content by mass is Mo, The powder material contains: 70-85% by mass of the first powder, 5 to 25% by mass of the second powder, and 5 to 25% by mass of the third powder.

2. The method according to claim 1, wherein The first powder contains 2.5 to 4.0 mass % of B and 3.0 to 5.0 mass % of Si.

3. The method according to claim 1, wherein The second powder is tungsten carbide cermet, and the total content of W and C is 70 mass % or more.

4. The method according to claim 1, wherein The third powder contains 10 to 30 mass % of Cr or 5 to 20 mass % of Mo.

5. A self-fluxing alloy film, wherein: The self-fluxing alloy film is formed using the production method according to any one of claims 1 to 4.

6. A component of an ironmaking equipment, wherein: The member for iron and steel making equipment includes a self-fluxing alloy film formed on a base material using the manufacturing method according to any one of claims 1 to 4.

7. A component of a pig iron production facility, a steel production facility, or a non-ferrous metal refining facility, wherein: The member of the pig iron manufacturing facility, steel manufacturing facility, or non-ferrous metal refining facility includes a self-fluxing alloy film formed on a base material using the manufacturing method according to any one of claims 1 to 4.

8. A component of equipment for hot rolling of steel or non-ferrous metal, wherein: The member of the equipment for hot rolling of steel or non-ferrous metal is obtained by forming a self-fluxing alloy film on a base material using the manufacturing method according to any one of claims 1 to 4.

9. A component of a continuous casting device, wherein: The member of the continuous casting equipment has a self-fluxing alloy film formed on a base material using the manufacturing method according to any one of claims 1 to 4.

10. A powder material, wherein: The powder material is a powder material obtained by mixing a first powder, a second powder and a third powder. The first powder is one or more self-fluxing alloys selected from Ni-based self-fluxing alloys and Co-based self-fluxing alloys, wherein the self-fluxing alloy contains 0.8-4.5 mass % of B and 1.5-5.0 mass % of Si. The second powder is one or more selected from carbide ceramics and carbide cermets, The third powder is one or more selected from Cr, Mo, Fe, Ni, Co, and alloys containing any of these as a main component, but for alloys containing Ni as a main component and alloys containing Co as a main component, the Ni-based self-fluxing alloy and the Co-based self-fluxing alloy defined by the first powder are excluded. In the third powder, when the element with the largest content on a mass basis is Cr, Fe, Ni or Co, The powder material contains: 45-65% by mass of the first powder, 5 to 35% by mass of the second powder, and 5 to 50% by mass of the third powder, In the third powder, when the element with the largest content by mass is Mo, The powder material contains: 70-85% by mass of the first powder, 5 to 25% by mass of the second powder, and 5 to 25% by mass of the third powder.

11. The powder material according to claim 10, wherein The first powder contains 2.5 to 4.0 mass % of B and 3.0 to 5.0 mass % of Si.

12. The powder material according to claim 10, wherein The second powder is tungsten carbide cermet, and the total content of W and C is 70 mass % or more.

13. The powder material according to claim 10, wherein The third powder contains 10 to 30 mass % of Cr or 5 to 20 mass % of Mo.

14. The powder material according to any one of claims 10 to 13, wherein The powder material is a material used for self-fluxing alloy spraying.

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