Fusion casting wear-resistant composite ceramic melting process and detection method and system

Abstract

The invention provides a fusion casting wear-resistant composite ceramic melting process and a detection method and system. The process comprises the following steps: preparing silicon carbide chopped fibers; a silicon carbide fiber net is laid on the surface of the high-chromium cast iron mold base body; gradient layer preparation, slurry sealing treatment and infiltration compounding; the detection system comprises a matrix pretreatment detection module, a layer material preparation detection cabin, a sealing slurry quality monitoring station, a sintering composite monitoring system and an intelligent data center. The detection method adopts a multi-parameter joint detection mechanism: matrix surface roughness and fiber mesh gap laser positioning calibration; dynamically verifying the material component purity and the fiber orientation degree; sealing slurry thickness infrared temperature control interlocking; and interface layer growth and aerosol quenching are tracked in real time. And the intelligent center fuses multi-source data through an LSTM neural network, prejudges defects and dynamically optimizes process parameters, realizes accurate regulation and control of infiltration pressure and quenching gas-water ratio, and ensures that the material interface strength is greater than or equal to 1800MPa and the process volatility is less than or equal to 1.5%.

Description

Technical Field

[0001] This application relates to the field of composite materials technology, and in particular to a fusion casting process, testing method and system for wear-resistant composite ceramics. Background Technology

[0002] As industrial equipment develops towards higher temperatures, higher pressures, and higher wear levels, traditional single materials are no longer sufficient to meet the demands of extreme operating conditions. Taking catalytic cracking units in the petrochemical industry as an example, their internal wear-resistant liners must withstand temperatures exceeding 800°C and the strong impact and wear of catalyst particles. Existing alumina ceramics, due to their high brittleness and poor thermal shock resistance, have an average service life of less than six months. Although metal matrix composites improve toughness through fiber reinforcement, insufficient interfacial bonding strength leads to premature fiber failure, becoming a key bottleneck restricting performance. The difference in thermal expansion coefficients between ceramic and metal substrates leads to residual tensile stress during the solidification of the cladding layer. When this stress exceeds the material's fracture strength, cracks form. While commercially available laser cladding ceramic coating technologies improve compositional uniformity through pre-placed powders, they fail to address the stress concentration problem in the overlapping areas of multiple cladding layers. Furthermore, existing processes rely on mechanical interlocking or simple diffusion bonding, resulting in interfacial bonding strength far lower than that of the substrate material. Common ceramic-metal gradient composite materials, although designed to alleviate thermal stress through compositional gradients, have an interfacial transition layer thickness of up to 2mm, significantly reducing the overall material strength. Additionally, ceramic casting requires high temperatures of 1500-1800℃, and temperature fluctuations of ±10℃ can cause a 20% change in grain size. Traditional thermocouple temperature measurement suffers from lag and cannot provide real-time feedback on the molten pool temperature distribution. The viscoelastic properties of molten ceramics make melt flow behavior difficult to predict. While common numerical simulation methods can predict molten pool flow patterns, they do not consider the Marangoni effect driven by surface tension gradients, resulting in a still relatively high defect rate in actual castings. The current ASTM D7264 standard measures interfacial strength using the tensile method, but this introduces additional damage during sample preparation and is only applicable to planar interfaces. For complex three-dimensional composite ceramics, there is a lack of effective non-destructive testing methods. Traditional wear resistance testing uses the grinding wheel wear method or ball milling test, both of which are destructive tests and cannot provide real-time feedback on production parameters. They require standard samples to undergo 24-hour cyclic wear, which cannot guide online process adjustments. Therefore, developing a new technology system that integrates casting process optimization, multi-field coupling control, and online detection for wear-resistant composite ceramics has become a core technological breakthrough direction for high-end equipment. Summary of the Invention

[0003] This application provides a fusion casting process, testing method and system for wear-resistant composite ceramics, to solve the problems mentioned in the background art.

[0004] To address the aforementioned technical problems, this application discloses a fusion casting process for wear-resistant composite ceramics, comprising the following steps:

[0005] S1. Preparation of silicon carbide short fiber: Polycarbosilane, nano-zirconia, boric acid and carbon nanotubes are melt-blended, and β-SiC grain fiber is obtained by spinning, oxidative crosslinking and sintering. After activation by silane coupling agent, it is woven into fiber web.

[0006] S2. Matrix pretreatment: Ceramic is laid flat on the surface of the high-chromium cast iron mold matrix, and silicon carbide fiber mesh is laid flat on the ceramic;

[0007] S3. Gradient layer preparation: Prepare surface layer, transition layer and protective layer materials respectively, and form a fiber gradient distribution by magnetic field orientation and centrifugal orientation;

[0008] S4. Sealing treatment: A sealing layer is formed by impregnation with high-alumina silica mortar.

[0009] S5. Melting and Infiltration Composite: Molten metal is poured under vacuum and pressurized and kept at a constant temperature to form a chromium carbide interface transition layer, followed by gas mist quenching.

[0010] Furthermore, the silicon carbide chopped fiber comprises 88.5 parts polycarbosilane, 6 parts nano-zirconia, 3 parts boric acid and 0.5 parts carbon nanotubes. After melt spinning at 180-220℃, it is sintered in an Ar / H2 atmosphere at 1450℃. The fiber diameter is 12μm and the chopped length is 0.5-2.0mm.

[0011] Furthermore, in step S3: the surface layer material contains 3.0-3.5 parts by weight of 200-mesh high alumina powder, 5 parts of silicon carbide fiber and silica sol, and is oriented using a 0.5T magnetic field to achieve a fiber orientation degree of ≥85%; the transition layer contains 2.5-3.0 parts of high alumina powder and 8 parts of fiber, and is centrifuged at 500 rpm to form a radial gradient; the protective layer contains 2.0-2.5 parts of high alumina powder and 12 parts of fiber, and the fiber volume fraction gradient change after centrifugation and orientation is ≥15%.

[0012] Furthermore, the viscosity of the silica sol is 1200 cP for the surface layer, 800 cP for the transition layer, and 600 cP for the protective layer, the material stirring time is ≥4h, and the humidity is controlled at 30-50%.

[0013] Furthermore, the melting and infiltration conditions in step S5 are: vacuum degree ≤10Pa, pressure of 0.8MPa and heat preservation for 3h, chromium carbide transition layer thickness of 2-5μm, gas mist quenching cooling rate of 18±0.5℃ / s, and droplet diameter of 50-80μm.

[0014] A detection system for the fusion casting wear-resistant composite ceramic melting process includes:

[0015] Substrate pretreatment detection module: integrates white light interferometer and laser scanning positioning system to detect substrate roughness Ra≤0.8μm and fiber mesh gap ±50μm in real time;

[0016] Layered material preparation and testing chamber: Equipped with X-ray fluorescence spectrometer and microfocus CT to verify material purity and fiber distribution;

[0017] Grouting quality monitoring station: The thickness of the sealing layer is monitored to be 0.3±0.05mm using an ultrasonic thickness gauge and an infrared thermal imager;

[0018] Sintering composite monitoring system: Tracks interface reactions and quenching processes using a high-temperature electron probe and a high-speed camera;

[0019] Intelligent data hub: Runs LSTM neural network to optimize process parameters, achieving a total process volatility of ≤1.5%.

[0020] Furthermore, the matrix pretreatment detection module is equipped with a pneumatic fine-tuning mechanism that automatically triggers position correction when the fiber mesh gap exceeds ±50μm, with a positioning accuracy of ±5μm; the layer material detection chamber is equipped with a dynamic adjustment mechanism that automatically adjusts the magnetic field strength to 0.3-0.7T or the centrifugal speed to ±20rpm when the radial distribution gradient Δρ of the CT scan is greater than 8%; the sealing quality monitoring station is equipped with a closed-loop control system for the dipping speed that automatically adjusts the dipping speed to ±5mm / s when the ultrasonic thickness measurement deviation is greater than 0.05mm; the sintering monitoring composite system includes a high-temperature EPMA interlocking device that automatically adjusts the heat preservation time to ±15min when the chromium carbide layer thickness exceeds the range of 2-5μm; and the intelligent data center constructs a digital twin model to predict interface defects and generate an optimized parameter set, including a melting and infiltration pressure of 0.5-1.2MPa and a quenching air-water ratio of 1:2-1:4.

[0021] A testing method for the fusion casting process of wear-resistant composite ceramics includes the following steps:

[0022] a) Joint inspection of substrate pretreatment: The surface roughness of the substrate Ra≤0.8μm was detected by white light interferometer, the fiber mesh gap deviation was scanned by laser confocal microscope ±50μm, and the joint bonding strength of the nodes was verified by tension tester ≥2.3N;

[0023] b) Multimodal testing of layer materials: The purity of high-alumina powder Al2O3 was verified by X-ray fluorescence spectrometry to be ≥99.2%, the viscosity of the surface layer material was measured by rotational rheometer to be 1200±50 cP, and the radial distribution gradient Δρ of the transition layer fibers was analyzed by CT tomography to be ≥15%.

[0024] c) Closed-loop monitoring of sealing: Combined with infrared thermal imager to control the immersion temperature at 65±2℃, ultrasonic thickness gauge to dynamically adjust the sealing layer thickness at 0.3±0.05mm, and contact angle meter to ensure that the surface wetting angle θ≤15°;

[0025] d) Interlock monitoring of sintering process: The growth rate of Cr3C2 interface layer was tracked in real time using a high-temperature electron probe (0.8-1.2 μm / min), a high-speed camera was used to monitor the diameter of the gas mist quenching droplets (50-80 μm), and a multi-channel temperature sensor was used to verify the cooling rate (18±0.5℃ / s).

[0026] e) Data fusion optimization: Input the detection data from steps a)-d) into the LSTM neural network to predict the probability of interface defects and generate process parameter correction instructions to achieve automatic tuning of melting and infiltration pressure of 0.5-1.2MPa and quenching air-water ratio of 1:2-1:4.

[0027] Furthermore, in step b): when the CT scan shows a radial distribution gradient Δρ > 8%, a magnetic field strength compensation mechanism is triggered, increasing the magnetic field to 0.7T at a rate of 0.1T / 3%CV; when the material viscosity is detected to exceed ±50cP, silica sol regulator is automatically added, with the addition amount calculated as Δη × 0.08mL / cP.

[0028] Furthermore, in step d): a feedback interlock is set between the high-temperature EPMA and the pressure system. When the Cr3C2 layer thickness reaches 5μm, pressurization is immediately terminated and air mist quenching is started. If the Cr element diffusion gradient at the interface is >3at.% / μm, the holding time is extended to ΔT=(G-3)×5min, where G is the measured gradient value (at.% / μm). In step e): the LSTM neural network analyzes the temperature field distribution with a time resolution of 20ms. When the predicted thermal stress concentration factor Kt≥1.5, the air mist spray angle is dynamically adjusted by ±15°, and the quenching water pressure is increased to 0.5MPa, so that the cooling rate is increased to 22℃ / s.

[0029] Compared with the prior art, this application provides a fusion casting wear-resistant composite ceramic melting process and testing method and system, which has the following beneficial effects:

[0030] 1. The silicon carbide short-cut fibers prepared in this application exhibit a synergistic effect of 6% nano-ZrO2 + 0.5% CNT: nano-ZrO2 inhibits abnormal growth of β-SiC grains, while CNT enhances fiber conductivity (surface resistance ≤10 Ω·cm). 3 The KH550 modification increases the magnetic field orientation efficiency by 3 times and improves the fiber temperature resistance to 1650℃ (traditional fibers ≤1500℃). The KH550 modification also increases the bonding strength between the fiber and silica sol to 11.8MPa (untreated fibers only 9.3MPa). This results in a fiber web with high weaving strength, fast magnetic field orientation, and strong melt-infiltration bonding.

[0031] 2. The system in this application integrates multimodal detection methods such as optics, acoustics, thermodynamics, and microscopic analysis to construct a full-process, multidimensional data acquisition network. The complementary design of different detection modules overcomes the limitations of traditional single-parameter detection, realizing comprehensive quality monitoring from matrix pretreatment to melt infiltration and composite bonding. Synchronous calibration of surface morphology and fiber distribution eliminates the hidden dangers of poor interfacial contact, while dynamic verification of material composition and fiber orientation ensures the stability of the gradient structure from the perspective of intrinsic material properties. This multidimensional joint inspection mechanism effectively improves the early identification rate of process defects and avoids the error accumulation problem caused by traditional segmented detection. Detailed Implementation

[0032] The preferred embodiments of this application are described below. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit this application.

[0033] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit this application. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0034] Unless otherwise specified, the examples and comparative examples are parallel experiments with the same components, component content, preparation steps, and preparation parameters. The experimental methods in the following examples are conventional methods unless otherwise specified. Unless otherwise specified, the experimental materials used in the following examples are analytical reagents (AR) and were all purchased from commercial channels.

[0035] High-chromium cast iron is KmTBCr26, with Cr 23-30% and C 2.0-3.3%; the polycarboxylate dispersant is BASF. Ultra PX 4275.

[0036] Example 1: Fusion casting process for wear-resistant composite ceramics:

[0037] S1. Preparation of silicon carbide chopped fibers: 88.5 parts of polycarbosilane (Mn = 1900 ± 50), 6 parts of composite nano-zirconia (20-30 nm tetragonal phase), 3 parts of ultrafine boric acid, and 0.5 parts of multi-walled carbon nanotubes were added to a twin-screw reactive extruder and melt-blended at 80 rpm under a temperature gradient of 180-220℃. The resulting fibers were spun through a 0.08 mm orifice spinneret at 250℃ under nitrogen protection at 15 MPa. Primary fibers with a diameter of 12 μm were obtained through a 4.2-fold draw. The fibers were then spun in a three-stage gradient at 160-210℃. Humidity-controlled crosslinking is carried out in an oxidation furnace with an oxygen concentration of 18-30%, followed by gradient sintering at 1450℃ / 85% Ar + 15% H2 atmosphere to form a β-SiC grain structure. The nano-zirconia activation solution containing 2.5% KH560 silane coupling agent is ultrasonically treated at 65℃ for 25 minutes, and then precisely cut into 0.5-2.0mm short silicon carbide chopped fibers by a laser positioning chopped machine. The fibers are then woven into a 20×20 mesh using a fully automatic rapier loom with a tension of 2.5N / strand, and the fiber nodes are strengthened by heat setting at 500℃ to form a silicon carbide fiber web.

[0038] S2. Substrate pretreatment: Select dense ceramic sheet material and spread it evenly on the surface of the high-chromium cast iron mold substrate, and then spread silicon carbide fiber mesh.

[0039] S3. Gradient Layer Preparation: At a temperature of 25-30℃ and a humidity of 30-50%, 3-3.5 parts by weight of 200-mesh high-alumina powder, 5 parts by weight of silicon carbide chopped fibers, and 1 part by weight of a silica sol solution with a viscosity of 1200 cP are mixed and stirred for 4 hours to prepare the surface layer material. 2.5-3 parts by weight of 200-mesh high-alumina powder, 8 parts by weight of silicon carbide chopped fibers, and 1 part by weight of a silica sol solution with a viscosity of 800 cP are mixed and stirred for 4 hours to prepare the transition layer material. 2-2.5 parts by weight of 200-mesh high-alumina powder, ... A protective and reinforcing layer material was prepared by mixing 12 parts of silicon carbide chopped fibers and 1 part of silica sol solution with a viscosity of 600 cP for 4 hours. The surface layer, transition layer and protective and reinforcing layer materials were then applied to the silicon carbide fiber mesh in sequence. When applying the surface layer material, a magnetic field orientation (intensity 0.5T) was used to align the fibers in the horizontal direction (orientation degree ≥85%). When applying the transition layer and protective layer materials, centrifugal orientation (speed 500 rpm × 3 min) was used to form ceramic fibers with a radial gradient distribution.

[0040] S4. Sealing treatment: Prepare the material by weight of 52 parts of 200-mesh high alumina powder, 48 parts of silica mortar with 65% solid content and 0.5 parts of dispersant (polycarboxylate), dip-coat and let stand to dry;

[0041] S5. Melting and Infiltration Composite: High-chromium cast iron is melted at 1550℃ and stirred at 250rpm to obtain a molten metal. Ceramic fibers are placed in a calcining furnace and calcined at 400-500℃ with nitrogen gas for 2 hours. The temperature is then raised to 960℃ and a vacuum of 10Pa is applied. Molten metal is poured in, and a pressure of 0.8MPa is applied. The temperature is maintained for 3 hours to form a 2-5μm thick Cr3C2 transition layer at the fiber-metal interface. The material is then quenched with air mist at a water pressure of 0.4MPa and an air-water ratio of 1:3, with a cooling rate of 18℃ / s to obtain a wear-resistant composite ceramic material.

[0042] Example 2: The difference from Example 1 lies in S3, gradient layer preparation: At a temperature of 25°C and a humidity of 30%, 3 parts by weight of 200-mesh high-alumina powder, 4 parts of silicon carbide chopped fibers, and 0.8 parts of silica sol solution with a viscosity of 1200 cP were mixed and stirred for 4 hours to prepare the surface layer material. 2.5 parts of 200-mesh high-alumina powder, 7 parts of silicon carbide chopped fibers, and 0.8 parts of silica sol solution with a viscosity of 800 cP were mixed and stirred for 4 hours to prepare the transition layer material. 2 parts of 200-mesh high-alumina powder, 10 parts of silicon carbide chopped fibers, and 0.8 parts of silica sol solution with a viscosity of 600 cP were mixed and stirred for 4 hours to prepare the protective and reinforcing layer material. The rest is the same.

[0043] Example 3: The difference from Example 1 lies in S3, gradient layer preparation: At a temperature of 30°C and a humidity of 50%, 3.5 parts by weight of 200-mesh high-alumina powder, 6 parts by weight of silicon carbide chopped fibers, and 1.2 parts by weight of a silica sol solution with a viscosity of 1200 cP were mixed and stirred for 4 hours to prepare the surface layer material. 3 parts by weight of 200-mesh high-alumina powder, 6 parts by weight of silicon carbide chopped fibers, and 1.2 parts by weight of a silica sol solution with a viscosity of 800 cP were mixed and stirred for 4 hours to prepare the transition layer material. 2.5 parts by weight of 200-mesh high-alumina powder, 14 parts by weight of silicon carbide chopped fibers, and 1.2 parts by weight of a silica sol solution with a viscosity of 600 cP were mixed and stirred for 4 hours to prepare the protective and reinforcing layer material. The rest is the same.

[0044] Example 4

[0045] A testing method for the fusion casting process of wear-resistant composite ceramics includes:

[0046] (I) Substrate pretreatment inspection: Surface roughness inspection: The Ra value of the high-chromium cast iron mold substrate is detected using a white light interferometer (resolution 0.1nm) (≤0.8μm), and the gap of the silicon carbide fiber mesh is verified by laser confocal microscopy (allowable error ±50μm); Fiber mesh structure inspection: The mesh count is scanned by a fully automatic image analysis system (20±0.5 mesh), and the joint strength of the nodes is tested by a tension tester (≥2.3N / node).

[0047] (II) Layer material preparation and testing: Raw material composition verification: X-ray fluorescence spectrometry (XRF) was used to detect the Al2O3 content of high-alumina powder (≥99.2%), and laser particle size analyzer was used to monitor the D50 value of 200-mesh powder (74±2μm); Material performance testing: Rotational rheometer (25℃) was used to determine the viscosity of the surface layer material (1200±50cP); Fiber orientation detection: Surface layer: X-ray diffraction analysis of (002) crystal plane orientation factor (≥0.85); Transition layer: CT tomography scan of radial distribution gradient (Δρ≥15%);

[0048] (III) Quality monitoring of sealing: Infrared thermal imager to monitor the dipping temperature (65±2℃); ultrasonic thickness gauge to detect the thickness of the sealing layer (0.3±0.05mm); contact angle meter to verify the surface wettability after drying (θ≤15°);

[0049] (iv) Sintering composite detection: Interface reaction monitoring: In-situ high temperature microscope observation of Cr3C2 layer growth (2-5μm); Electron probe microanalysis (EPMA) analysis of elemental diffusion gradient (Cr content change ≤3at.% / μm); Quenching process detection: High-speed camera recording of gas mist mixing uniformity (droplet diameter 50-80μm); Multi-channel temperature acquisition system monitoring cooling curve (18±0.5℃ / s).

[0050] Example 5

[0051] The testing system achieves closed-loop control throughout the entire process through five modules, including: 1. A substrate pretreatment testing module, using a white light interferometer (ZygoNewView9000) and a laser scanning positioning system to detect the surface roughness (Ra≤0.8μm) and silicon carbide fiber mesh gap (±50μm) of the high-chromium cast iron mold substrate in real time. If the tolerances are exceeded, mechanical polishing or pneumatic fine-tuning is automatically triggered; 2. A layer material preparation testing chamber, using an X-ray fluorescence spectrometer (PANalyticalEpsilon4) and a microfocus CT (NikonXTH225) to verify the purity of high-alumina powder (Al2O3≥99.2%) and fiber orientation (surface layer orientation factor≥0.85, transition layer CV value≤8%), dynamically adjusting the magnetic field strength (0.3-0.7T) or centrifugal speed (±20rpm); 3. A sealing quality monitoring station, using an ultrasonic thickness gauge (Olympus38DLPLU). S) and infrared thermal imager (FLIRA655sc) monitor the grout thickness (0.3±0.05mm) and temperature uniformity (65±2℃), and adjust the dipping speed (±5mm / s) in linkage when defects exceed the limit; 4. Sintering composite monitoring system, which tracks the Cr3C2 transition layer thickness (2-5μm) and the diameter of the gas mist quenching droplets (50-80μm) in real time through high-temperature electron probe (JEOLJXA-8530F) and high-speed camera (PhotronFASTCAM), and automatically corrects the holding time or gas mist pressure (0.3-0.5MPa) using PID algorithm; 5. Intelligent data hub, which runs LSTM neural network and digital twin model on industrial server (Dell PowerEdgeR750) to predict interface defects and optimize process parameters, achieving a full-process fluctuation rate of ≤1.5%, and ultimately ensuring the wear resistance of materials (≥1800HV) and process stability.

[0052] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. If such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A fusion casting process for wear-resistant composite ceramics, characterized in that, The process integrates shell casting, lost foam casting, and wax casting, and includes the following steps: a high-chromium cast iron mold base is prepared by shell casting; a ceramic layer is laid on the surface of the base using lost foam casting; a silicon carbide fiber positioning structure is prepared using wax casting; the fiber mesh is pre-embedded in a low-temperature wax mold; a three-dimensional fiber arrangement is formed by investment casting; surface layer, transition layer, and protective layer materials are prepared separately; a sealing layer is formed by impregnation with high-alumina silica slurry; molten metal is poured under vacuum and pressurized and heat-insulated by gas mist quenching to achieve metallurgical infiltration and composite at the ceramic-metal interface.

2. The process according to claim 1, characterized in that, The process also includes: preparation of silicon carbide chopped fibers: polycarbosilane, nano-zirconia, boric acid and carbon nanotubes are melt-blended, and β-SiC crystalline fibers are obtained by spinning, oxidative crosslinking and sintering. After activation by silane coupling agent, the fibers are woven into a fiber web; matrix pretreatment: silicon carbide fiber web is laid flat on ceramic; gradient layer preparation: fiber gradient distribution is formed by magnetic field orientation and centrifugal orientation; melt infiltration composite: molten metal is poured under vacuum and pressurized and kept at a constant temperature to form a chromium carbide interface transition layer, followed by gas mist quenching; the silicon carbide chopped fibers by weight include 88.5 parts polycarbosilane, 6 parts nano-zirconia, 3 parts boric acid and 0.5 parts carbon nanotubes. After melt spinning at 180-220℃, the fibers are sintered in an Ar / H2 atmosphere at 1450℃. The fiber diameter is 12μm and the chopped length is 0.5-2.0mm.

3. The process according to claim 1, characterized in that, The surface material contains 200-mesh high alumina powder, silicon carbide fiber and silica sol, and is oriented by a 0.5T magnetic field to achieve a fiber orientation degree of ≥85%; the transition layer contains high alumina powder and fiber, and is centrifuged at 500 rpm to form a radial gradient. The protective layer contains high-alumina powder and fibers, and the fiber volume fraction gradient change is ≥15% after centrifugation and orientation.

4. The process according to claim 3, characterized in that, The viscosity of the silica sol is 1200 cP for the surface layer, the material stirring time is ≥4h, and the humidity is controlled at 30-50%.

5. The process according to claim 2, characterized in that, The melting and infiltration conditions are: vacuum degree ≤10Pa, pressure 0.8MPa and heat preservation for 3h, chromium carbide transition layer thickness 2-5μm, air mist quenching cooling rate 18±0.5℃ / s, and droplet diameter 50-80μm.

6. A testing system for the fusion casting process of wear-resistant composite ceramics, characterized in that, include: Substrate pretreatment detection module: integrates white light interferometer and laser scanning positioning system to detect substrate roughness Ra≤0.8μm and fiber mesh gap ±50μm in real time; Layered material preparation and testing chamber: Equipped with X-ray fluorescence spectrometer and microfocus CT to verify material purity and fiber distribution; Grouting quality monitoring station: The thickness of the sealing layer is monitored to be 0.3±0.05mm using an ultrasonic thickness gauge and an infrared thermal imager; Sintering composite monitoring system: Tracks interface reactions and quenching processes using a high-temperature electron probe and a high-speed camera; Intelligent data hub: Runs LSTM neural network to optimize process parameters, achieving a total process volatility of ≤1.5%.

7. The detection system according to claim 6, characterized in that, The matrix pretreatment detection module is equipped with a pneumatic fine-tuning mechanism that automatically triggers position correction when the fiber mesh gap exceeds ±50μm, with a positioning accuracy of ±5μm. The layer material detection chamber is equipped with a dynamic adjustment mechanism that automatically adjusts the magnetic field strength to 0.3-0.7T or the centrifugal speed to ±20rpm when the radial distribution gradient Δρ of the CT scan is greater than 8%. The grouting quality monitoring station is equipped with a closed-loop control system for the dipping speed. When the ultrasonic thickness measurement deviation is greater than 0.05mm, the dipping speed is automatically adjusted to ±5mm / s. The sintering monitoring composite system includes a high-temperature EPMA interlocking device that automatically adjusts the heat preservation time to ±15min when the chromium carbide layer thickness exceeds the range of 2-5μm. The intelligent data center constructs a digital twin model to predict interface defects and generate an optimized parameter set, including a melting and infiltration pressure of 0.5-1.2MPa and a quenching air-water ratio of 1:2-1:

4.

8. A method for detecting the fusion casting process of wear-resistant composite ceramics, characterized in that, Includes the following steps: a) Joint inspection of substrate pretreatment: The surface roughness of the substrate Ra≤0.8μm was detected by white light interferometer, the fiber mesh gap deviation was scanned by laser confocal microscope ±50μm, and the joint bonding strength of the nodes was verified by tension tester ≥2.3N; b) Multimodal testing of layer materials: The purity of high-alumina powder Al2O3 was verified by X-ray fluorescence spectrometry to be ≥99.2%, the viscosity of the surface layer material was measured by rotational rheometer to be 1200±50 cP, and the radial distribution gradient Δρ of the transition layer fibers was analyzed by CT tomography to be ≥15%. c) Closed-loop monitoring of sealing: Combined with infrared thermal imager to control the immersion temperature at 65±2℃, ultrasonic thickness gauge to dynamically adjust the sealing layer thickness at 0.3±0.05mm, and contact angle meter to ensure surface wetting angle θ≤15°; d) Interlock monitoring of sintering process: The growth rate of Cr3C2 interface layer was tracked in real time using a high-temperature electron probe (0.8-1.2 μm / min), a high-speed camera was used to monitor the diameter of the gas mist quenching droplets (50-80 μm), and a multi-channel temperature sensor was used to verify the cooling rate (18±0.5℃ / s). e) Data fusion optimization: Input the detection data of the ad step into the LSTM neural network to predict the probability of interface defects and generate process parameter correction instructions to achieve automatic tuning of melting and infiltration pressure of 0.5-1.2MPa and quenching air-water ratio of 1:2-1:

4.

9. The detection method according to claim 8, characterized in that, In step b): when the CT scan shows a radial distribution gradient Δρ > 8%, the magnetic field strength compensation mechanism is triggered, and the magnetic field is increased to 0.7T at a rate of 0.1T / 3%CV; when the material viscosity is detected to be outside the range of ±50cP, silica sol regulator is automatically added, and the amount added is calculated according to Δη×0.08mL / cP.

10. The detection method according to claim 8, characterized in that, In step d): a feedback interlock is set between the high-temperature EPMA and the pressure system. When the Cr3C2 layer thickness reaches 5μm, pressurization is immediately terminated and air mist quenching is started. If the Cr element diffusion gradient at the interface is >3at.% / μm, the holding time is extended to ΔT=(G-3)×5min, where G is the measured gradient value (at.% / μm). In step e): the LSTM neural network analyzes the temperature field distribution with a time resolution of 20ms. When the predicted thermal stress concentration factor Kt≥1.5, the air mist spray angle is dynamically adjusted by ±15°, and the quenching water pressure is increased to 0.5MPa, so that the cooling rate is increased to 22℃ / s.