A weldable wear-resistant assembly and a preparation method thereof, and a wear-resistant hammer piece for a feed crusher and a preparation method thereof

Abstract

This application relates to the field of mechanical parts manufacturing, mainly to a weldable wear-resistant component and its preparation method, and a wear-resistant hammer for a feed crusher and its preparation method. A weldable wear-resistant component includes a metal base layer, a metal-ceramic transition layer, and a metal-ceramic wear-resistant surface layer, sequentially fixedly connected. The metal-ceramic transition layer comprises, by mass fraction, 75-95% transition layer metal components, with the remainder being transition layer ceramic components. The metal-ceramic wear-resistant surface layer comprises, by mass fraction, 35-70% adhesive alloy powder, with the remainder being wear-resistant surface layer ceramic components. The technical solution of this application, to further improve hardness and wear resistance while solving production efficiency issues, adopts a three-layer composite structure and uses a sintering process to prepare the weldable wear-resistant component. Finally, welding is used to bond the weldable wear-resistant component to the hammer substrate. This can effectively improve the hardness and toughness of the wear-resistant hammer for the feed crusher, making it more wear-resistant.

Description

Technical Field

[0001] This application relates to the field of mechanical parts manufacturing, and mainly to a weldable wear-resistant component and its preparation method, and a wear-resistant hammer for a feed crusher and its preparation method. Background Technology

[0002] The feed processing industry is a vital pillar of modern animal husbandry and aquaculture. With the continuous growth in global demand for meat, eggs, and dairy products, feed production is expanding, placing higher demands on the performance and efficiency of feed processing equipment. As a key piece of equipment in the feed production line, the feed crusher's core component—the hammer mill—directly participates in the crushing and pulverizing process, playing a decisive role in the particle size, uniformity, and production efficiency of the feed. However, under long-term, high-load, and high-frequency operation, the hammer mill faces severe wear problems, becoming a key factor restricting stable equipment operation and production cost control.

[0003] Existing solutions also have some limitations: 1) Single material improvement: While increasing material hardness can improve wear resistance, it may sacrifice toughness, leading to an increased risk of brittle fracture. In practice, it has been found that some alloy materials, although hard enough, are prone to cracking under complex stress, affecting their actual performance.

[0004] 2) Surface Coating Technology: Traditional coatings (such as electroplating and thermal spraying) suffer from insufficient bonding strength and are prone to peeling, making them unable to withstand high-impact and abrasive wear environments. Especially when handling high-hardness materials, the coating peels off more quickly, significantly increasing maintenance costs.

[0005] 3) Welding repair: Manual welding is inefficient and easily generates welding stress, leading to deformation or cracks in the hammer blades and affecting their service life. In addition, due to the unevenness of the welded area, the wear rate is also faster, resulting in unsatisfactory repair results.

[0006] Therefore, existing technologies still need to be improved and developed. Summary of the Invention

[0007] In view of the shortcomings of the prior art, the purpose of this application is to provide a weldable wear-resistant component and its preparation method, and a wear-resistant hammer for a feed crusher and its preparation method, aiming to improve the hardness and toughness of the wear-resistant hammer for a feed crusher, making it more wear-resistant.

[0008] Traditional wear-resistant components are directly welded onto the substrate. To avoid significant differences in composition, the ceramic content of the wear-resistant layer is strictly controlled in traditional welding. This application's technical solution, to further improve hardness and wear resistance while addressing production efficiency issues, employs a three-layer composite structure and uses a sintering process to prepare weldable wear-resistant components. Finally, welding is used to bond the weldable wear-resistant components to the hammer blade substrate.

[0009] The technical solution of this application is as follows: A weldable wear-resistant component includes a metal underlayer, a metal-ceramic transition layer, and a metal-ceramic wear-resistant surface layer that are fixedly connected in sequence. The metal-ceramic transition layer comprises the following components by mass fraction: 75-95% transition layer metal component, with the balance being transition layer ceramic component; The metal-ceramic wear-resistant surface layer comprises the following components by mass fraction: 35-70% binder alloy powder, with the remainder being the wear-resistant surface layer ceramic component.

[0010] Furthermore, the chemical composition of the metal underlayer is as follows (by mass percentage): C 0.2–1.0%, B 0.001–0.005%, Cr 0.2–2.4%, Mo 0.002–0.01%, Si 0.2–1%, Mn 1–2.2%, Ti 0.02–1%, Ni 2–18%, S≤0.01%, P≤0.02%, Y3O2≤0.1%, with the balance being Fe, and unavoidable impurity elements.

[0011] Furthermore, the chemical composition of the transition layer metal component by mass percentage is as follows: C 0.5-1.2%, B 3-7.2%, Cr 11-17%, Si 3-4.5%, Mn 0.1-0.2%, Fe 4-8.7%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, with the balance being Ni, and unavoidable impurity elements; The transition layer ceramic composition includes one or a mixture of two of titanium carbide powder and tungsten carbide powder.

[0012] Furthermore, the chemical composition of the adhesive alloy powder by mass percentage is as follows: C 0.5-1.2%, B 3-7.2%, Cr 11-17%, Si 3-4.5%, Mn 0.1-0.2%, Fe 4-8.7%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, with the balance being Ni and unavoidable impurity elements; The wear-resistant surface layer ceramic composition includes one or a mixture of two of titanium carbide powder and tungsten carbide powder.

[0013] The metal underlayment uses a combination of Fe-based and reinforced alloy systems to adapt to the hammer blade substrate and strengthen the interface. The metal underlayment uses Fe as the matrix, with added Cr, Mo, Ti, etc., to form a corrosion-resistant and heat-resistant alloy framework. For example, Cr forms a Cr2O3 passivation film on the surface to improve oxidation resistance; Mo enhances high-temperature strength through solid solution strengthening; and Ti combines with C and N to form TiC and TiN second-phase particles to refine the grain size. Y3O2, as a rare earth oxide, can purify grain boundaries and inhibit impurity segregation. Combined with the deoxidation and desulfurization effects of Si and Mn, it significantly improves the metallurgical bonding strength between the metal underlayment and the hammer blade substrate. Boron element increases hardness through solid solution strengthening and boride precipitation, while synergistically improving weldability with Ni, ensuring reliable welding to the hammer blade substrate.

[0014] The cermet transition layer employs a combination of Ni-based and carbide components, providing excellent stress buffering and wear-resistant transition. Ni serves as the primary metallic matrix (balance), supplemented with Cr, Si, and Mn for corrosion-resistant solid solution strengthening, while Fe acts as a low-cost alloying element to regulate the coefficient of thermal expansion. The ceramic phase exhibits a TiC / WC gradient; TiC provides high hardness and wear resistance, while WC absorbs impact energy through high toughness (compared to TiC). Y3O2 promotes liquid phase wetting during sintering, ensuring uniform ceramic particle distribution. B and C elements react with Ni to form the Ni3(B,C) hard phase, further enhancing the hardness gradient of the transition layer and achieving a smooth transition from the pure metal underlayer to the cermet wear-resistant surface layer.

[0015] The cermet wear-resistant surface layer employs a combination of high ceramic content and high Ni base, exhibiting excellent wear resistance and self-healing effects. The ceramic content of the cermet wear-resistant surface layer is increased to 35-70% (TiC, WC), forming a continuous wear-resistant skeleton through high volume fraction carbides. Cr and Si in the Ni matrix form a dense oxide film (Cr2O3, SiO2) to enhance oxidation resistance, while Mo strengthens high-temperature hardness through solid solution. During wear, TiC and WC particles are gradually exposed, forming a hard "skeleton" structure, which, combined with the plastic deformation of Ni, achieves a self-sharpening effect that resists wear through wear. Y3O2, under high-temperature sintering, promotes grain boundary migration, forming a fine-grained structure and improving fatigue resistance.

[0016] This application also provides a method for preparing a weldable wear-resistant component, comprising the following steps: The metal underlay material is prepared according to the required proportion of the chemical composition mass percentage of the metal underlay material, and then ball-milled to obtain metal underlay powder. The transition layer metal component is prepared according to the required mass percentage of the chemical composition of the transition layer metal component to obtain the transition layer metal component material; the transition layer metal component material and the transition layer ceramic component are mixed to obtain the metal-ceramic transition layer material; and ball milling is performed to obtain the metal-ceramic transition layer powder. The adhesive alloy powder is prepared according to the required proportion of the chemical composition by mass percentage to obtain the adhesive alloy powder; the wear-resistant surface layer ceramic component is mixed with the adhesive alloy powder to obtain the metal-ceramic wear-resistant surface layer material; ball milling is performed to obtain the metal-ceramic wear-resistant surface layer powder. The metal underlay powder is pressed to obtain the metal underlay. The metal-ceramic transition layer powder is further pressed to obtain the metal-ceramic transition layer; The metal-ceramic wear-resistant surface powder is then pressed to form the metal-ceramic wear-resistant surface layer, and a pressed product is obtained. The pressed product is sintered to obtain the weldable wear-resistant component.

[0017] Furthermore, the metal underlay powder is pressed under a pressure of 150-250MPa and kept at a constant pressure for 1-5 minutes to obtain the metal underlay. The metal-ceramic transition layer powder is pressed under a pressure of 50-150MPa and kept under constant pressure for 1-5 minutes to obtain the metal-ceramic transition layer. The metal-ceramic wear-resistant surface powder is pressed under a pressure of 50-150MPa and kept under constant pressure for 1-5 minutes to form the metal-ceramic wear-resistant surface layer.

[0018] Furthermore, the pressed product is sintered under vacuum and constant pressure conditions at a sintering temperature of 1250℃-1350℃. The sintering process is as follows: heating rate of 5-10℃ / min, sintering time of 2.5-4.5 hours, and holding time of 10-30 minutes; thus obtaining the weldable wear-resistant component.

[0019] Furthermore, the constant pressure is 20-40 MPa.

[0020] This application employs vacuum hot pressing sintering, achieving mechanical interlocking and chemical bonding between TiC, WC, and the Ni matrix in the metal-ceramic transition layer through three-stage temperature control, resulting in the densification of the high-ceramic phase in the metal-ceramic wear-resistant surface layer. During sintering, B and Si elements form a low-melting-point eutectic, promoting liquid-phase sintering and increasing density.

[0021] This application also provides a wear-resistant hammer for a feed crusher, including a hammer substrate and a weldable wear-resistant component, wherein the side of the hammer substrate is fixedly connected to the side of the metal underlayer of the weldable wear-resistant component that is away from the metal-ceramic transition layer.

[0022] This application also provides a method for preparing wear-resistant hammers for a feed crusher, wherein the hammer substrate and the metal underlayer of the weldable wear-resistant component are assembled by welding to obtain wear-resistant hammers for a feed crusher.

[0023] By matching the composition of the metal underlayer and the hammer blade substrate (Fe-Cr-Ni system), laser welding is used to achieve a low-heat-input, high-precision connection, effectively reducing welding residual stress and controlling deformation to within 0.5mm. An Fe-Cr-Ni solid solution strengthening phase is formed in the welded area, significantly improving bonding strength and enhancing resistance to spalling.

[0024] The production method provided in this application mainly utilizes powder metallurgy to mass-produce weldable wear-resistant components. Compared to the single-piece production cycle of mainstream welding processes, production efficiency is significantly improved. Secondly, because the weldable wear-resistant components prepared by powder metallurgy have multi-layered compositional transitions, they also exhibit high surface wear resistance in terms of mechanical properties. Furthermore, the welding interface between the weldable wear-resistant components and the hammer substrate has strong interfacial bonding strength and low interfacial stress, achieving excellent compatibility of mechanical properties. In contrast, the wear-resistant layer of wear-resistant hammers prepared by traditional welding processes suffers from excessive compositional differences at the interface, leading to thermal stress concentration and a very high risk of brittle fracture.

[0025] Compared with the prior art, this application has the following beneficial effects: 1. This application achieves a balance between hardness and toughness through a three-layer gradient composition design. The metal base layer is primarily iron-based, with added alloying elements such as chromium, molybdenum, and titanium forming a corrosion-resistant and heat-resistant framework. Rare earth oxides are used to purify grain boundaries and enhance the metallurgical bond strength with the substrate. The cermet transition layer employs a nickel-based + titanium carbide / tungsten carbide composite structure. The ceramic phase achieves a smooth transition in hardness, while the high toughness of tungsten carbide effectively absorbs impact energy, preventing brittle fracture. The cermet wear-resistant surface layer further increases the ceramic phase content, forming a continuous wear-resistant framework. Combined with a self-sharpening effect, it achieves wear resistance through wear, maintaining sufficient toughness while ensuring high wear resistance, thus solving the problem of the imbalance between hardness and toughness in traditional materials.

[0026] 2. The sintering process promotes atomic diffusion between layers through vacuum hot pressing and temperature control, forming a metallurgical bonding interface that effectively improves bonding strength compared to traditional coatings. The boron and nickel elements in the metal underlayer synergistically improve weldability. Combined with low-heat-input technologies such as laser welding, residual welding stress and deformation are reduced, and a solid solution-reinforced phase forms in the weld area, enhancing resistance to spalling. In the metal-ceramic transition layer, ceramic particles and metal form a composite structure through mechanical interlocking and chemical bonding, effectively buffering stress and ensuring long-term stable operation under high-impact and high-wear environments.

[0027] 3. The wear-resistant hammer blades for feed crushers provided in this application have an effectively extended service life, which can reduce the frequency of replacement, reduce maintenance costs, and improve the overall operating efficiency of feed processing equipment, thus having significant economic benefits and technical promotion value. Attached Figure Description

[0028] Figure 1This is a schematic diagram of the wear-resistant component of Embodiment 1 of this application and its assembly method with the hammer blade substrate.

[0029] Figure 2 This is a physical image of the wear-resistant hammer blades for a feed crusher according to Embodiment 1 of this application.

[0030] Labeling Explanation: 1. Metal base layer; 2. Metal-ceramic transition layer; 3. Metal-ceramic wear-resistant surface layer; 4. Hammer blade substrate. Detailed Implementation

[0031] This application provides a weldable wear-resistant component and its preparation method, as well as a wear-resistant hammer for a feed crusher and its preparation method. To make the objectives, technical solutions, and effects of this application clearer and more explicit, the following provides a further detailed description. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0032] This application provides a weldable wear-resistant component, comprising a metal underlayer 1, a metal-ceramic transition layer 2, and a metal-ceramic wear-resistant surface layer 3, which are fixedly connected in sequence.

[0033] The chemical composition of the metal underlayer 1 by mass percentage is as follows: C 0.2-1.0%, B 0.001-0.005%, Cr 0.2-2.4%, Mo 0.002-0.01%, Si 0.2-1%, Mn 1-2.2%, Ti 0.02-1%, Ni 2-18%, S≤0.01%, P≤0.02%, Y3O2≤0.1%, with the balance being Fe and unavoidable impurity elements.

[0034] The metal-ceramic transition layer 2 comprises the following components by mass fraction: 75-95% transition layer metal component, and the remainder is transition layer ceramic component.

[0035] The chemical composition of the transition layer metal is as follows (mass percentage): C 0.5–1.2%, B 3–7.2%, Cr 11–17%, Si 3–4.5%, Mn 0.1–0.2%, Fe 4–8.7%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, with the balance being Ni and unavoidable impurity elements.

[0036] The transition layer ceramic composition includes one or a mixture of titanium carbide powder and tungsten carbide powder.

[0037] The metal-ceramic wear-resistant surface layer 3 comprises the following components by mass fraction: 35-70% binder alloy powder, and the remainder is wear-resistant surface layer ceramic components.

[0038] The chemical composition of the adhesive alloy powder by mass percentage is as follows: C 0.5-1.2%, B 3-7.2%, Cr 11-17%, Si 3-4.5%, Mn 0.1-0.2%, Fe 4-8.7%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, with the balance being Ni and unavoidable impurity elements.

[0039] The wear-resistant surface layer ceramic composition includes one or a mixture of titanium carbide powder and tungsten carbide powder.

[0040] This application also provides a method for preparing a weldable wear-resistant component, comprising the following steps: Step 1: Preparation of metal underlay material: Boron iron powder, chromium iron powder, manganese iron powder, silicon iron powder, molybdenum iron powder, titanium powder, nickel powder, iron powder, colloidal graphite, and Y3O2 are mixed in the required proportions according to the chemical composition mass percentages of metal underlayment 1 to obtain the metal underlayment material.

[0041] Step 2: Preparation of metal-ceramic transition layer material: Step 2 (1): Prepare the transition layer metal component material by mixing ferroboron powder, ferrochrome powder, ferromanganese powder, ferrosilicon powder, nickel powder, iron powder, colloidal graphite, and Y3O2 in the required proportions according to the mass percentage of the chemical composition of the transition layer metal component. Step 2 (2): The transition layer metal component material and the transition layer ceramic component are mixed to obtain the metal-ceramic transition layer material.

[0042] Step 3: Preparation of metal-ceramic wear-resistant surface layer material: Step 3 (1): Prepare the adhesive alloy powder by mixing ferroboron powder, ferrochrome powder, ferromanganese powder, ferrosilicon powder, ferromolybdenum powder, nickel powder, iron powder, colloidal graphite, and Y3O2 according to the required proportion of chemical composition mass percentage of the adhesive alloy powder. (2) The wear-resistant surface ceramic component is mixed with the adhesive alloy powder to obtain the metal ceramic wear-resistant surface material.

[0043] Step 4: Preparation of metal underlayer powder: The metal underlay material is loaded into a ball mill, and steel balls are added at a ball-to-material ratio of 2:1 to 7:1. 40-60 wt% anhydrous ethanol is added as a medium and 0.1-1 wt% PVA is added as a coolant and dispersant. The mixture is ball-milled for 24-36 hours to obtain the metal underlay powder.

[0044] Step 5: Preparation of metal-ceramic transition layer powder: The metal-ceramic transition layer material is loaded into a ball mill and steel balls are added at a ball-to-material ratio of 4:1 to 9:1. 40-60 wt% anhydrous ethanol is added as a medium and 0.1-1 wt% PVA is added as a coolant and dispersant. The mixture is ball-milled for 24-48 hours to obtain the metal-ceramic transition layer powder.

[0045] Step 6: Preparation of metal-ceramic wear-resistant surface layer powder: The metal-ceramic wear-resistant surface material is loaded into a ball mill and steel balls are added. The ball-to-material ratio is 4:1-9:1. 40-60wt% anhydrous ethanol is added as a medium and 0.1-1wt% PVA is added as a coolant and dispersant. The mixture is ball-milled for 24-48 hours to obtain metal-ceramic wear-resistant surface powder.

[0046] Step 7: After drying and sieving the metal base layer powder, put it into a mold and press it under a pressure of 150-250MPa for 1-5 minutes to form the metal base layer 1.

[0047] After drying and sieving the metal-ceramic transition layer powder, it is placed into the upper part of the mold and pressed under a pressure of 50-150MPa for 1-5 minutes to form the metal-ceramic transition layer 2.

[0048] Finally, the metal-ceramic wear-resistant surface powder is dried, sieved, and placed into the upper part of the mold. It is then pressed under a pressure of 50-150MPa and kept under constant pressure for 1-5 minutes to obtain the desired shape, forming the metal-ceramic wear-resistant surface layer 3; at the same time, the pressed product is obtained.

[0049] Step 8: Place the pressed product into a matching ceramic sintering mold and sinter it under vacuum (preferably 10-3 Pa) and constant pressure of 20-40 MPa. The sintering temperature is 1250℃-1350℃, and the sintering process is as follows: heating rate 5-10℃ / min, sintering time 2.5-4.5h, holding temperature for 10-30min, and then cooling to room temperature with the furnace to obtain a weldable wear-resistant component.

[0050] This application also provides a wear-resistant hammer blade for a feed crusher. The wear-resistant hammer blade for the feed crusher includes a hammer blade substrate 4 and a weldable wear-resistant component. The hammer blade substrate 4 is fixedly connected to the weldable wear-resistant component.

[0051] Specifically, the side of the hammer blade substrate 4 is fixedly connected to the side of the metal underlayment 1 of the weldable wear-resistant component that is away from the metal-ceramic transition layer 2.

[0052] Preferably, the fixed connection method is welding. More preferably, it is laser welding.

[0053] The hammer blade substrate 4 should preferably be made of materials with low welding stress, such as steel or iron-based materials, with 65Mn being the most preferred.

[0054] This application also provides a method for preparing wear-resistant hammers for a feed crusher, including the following steps: assembling the hammer substrate 4 and the metal underlayer 1 of the weldable wear-resistant component by laser welding to obtain the wear-resistant hammers for the feed crusher.

[0055] This application utilizes various methods, including composition gradient design, sintering process adjustment, and welding interface optimization, to obtain wear-resistant hammer blades for feed crushers that combine toughness and hardness.

[0056] The metal base layer 1 is mainly iron-based, supplemented with alloying elements such as chromium, molybdenum, titanium, and nickel to reduce thermal stress mismatch. Molybdenum enhances high-temperature strength through solid solution strengthening, while titanium combines with carbon and nitrogen to form fine-grained second-phase particles to optimize the grain structure. Rare earth oxide Y3O2 purifies grain boundaries and inhibits impurity segregation. Combined with the deoxidation and desulfurization effects of silicon and manganese, it significantly improves the metallurgical bonding strength with the hammer blade substrate 4. At the same time, boron and nickel elements synergistically improve welding performance to ensure reliable connection.

[0057] The metal-ceramic transition layer 2 is primarily nickel-based, achieving a balanced transition between hardness and toughness through ceramic phases such as titanium carbide and tungsten carbide. Titanium carbide provides high hardness to support wear resistance, while tungsten carbide absorbs impact energy with high toughness. Combined with solid solution strengthening of chromium, silicon, and manganese, and liquid-phase wetting effect of Y3O2, this ensures uniform distribution of ceramic particles and the formation of a composite structure with mechanical interlocking and chemical bonding with the metal matrix, effectively buffering stress and improving resistance to spalling.

[0058] The cermet wear-resistant surface layer 3 further increases the ceramic phase content (35-70%) based on the cermet transition layer 2. It forms a continuous wear-resistant skeleton through high volume fractions of titanium carbide and tungsten carbide, combined with the oxide film construction of chromium and silicon in the nickel matrix and the solid solution strengthening of molybdenum, achieving high wear resistance and a self-sharpening effect. During wear, ceramic particles are gradually exposed, forming a micro-edge structure, which, combined with the plastic deformation of the metal matrix, achieves a continuous wear-resistant effect through wear resistance.

[0059] The sintering process replicates the atmosphere concentration and process control through vacuum hot pressing, which promotes the densification of the ceramic phase of the metal-ceramic transition layer 2 and the metal underlayer 1, as well as the densification of the high ceramic phase of the metal-ceramic wear-resistant surface layer 3. The low melting point eutectic formed by boron and silicon promotes liquid phase sintering, further improving the overall density and bonding strength.

[0060] Welding integration optimizes the composition matching between the metal underlayer 1 and the hammer blade substrate 4, adopts a low heat input and high precision welding method, reduces residual welding stress and deformation, strengthens the solid solution reinforcing phase in the welding area, and significantly improves the bonding strength and anti-peeling performance.

[0061] Ultimately, the three-layer composite weldable wear-resistant component achieves comprehensive improvements in wear resistance, impact resistance, bonding strength, corrosion resistance, and oxidation resistance. It effectively solves the pain points of traditional wear-resistant hammers, such as the imbalance between hardness and toughness, easy peeling of coating, and low welding efficiency. It extends the service life of wear-resistant hammers for feed crushers, reduces maintenance costs, and improves the overall performance and production efficiency of feed processing equipment. It has significant technical promotion value and economic benefits.

[0062] The present application will be further described below through specific embodiments.

[0063] Example 1 (1) Raw materials: The raw materials used are ferromolybdenum powder, ferroboron powder, ferromanganese powder, ferrochrome powder, ferrosilicon powder, iron powder, titanium powder, nickel powder, colloidal graphite, tungsten carbide powder, Y3O2, and PVA, with a powder particle size of 5-250μm; (2) Material preparation: 2.1. The composition ratio of the metal-ceramic wear-resistant surface material is: tungsten carbide powder 55%, binder alloy powder 45%.

[0064] The mass percentage of each element in the bonding alloy is as follows: C 0.75%, B 3.9%, Cr 13%, Si 3.2%, Mn 0.16%, Fe 6.2%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, with the balance being Ni.

[0065] 2.2. The chemical composition of the metal-ceramic transition layer material by mass percentage is as follows: C 0.75%, B 3.9%, Cr 13%, Si 3.2%, Mn 0.16%, Fe 6.2%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, 5% WC, balance Ni.

[0066] 2.3. The chemical composition (mass percentage) of the metal underlay material is as follows: C 0.26%, B 0.002%, Cr 0.26%, Mo 0.004%, Si 0.28%, Mn 1.06%, Ti 0.025%, Ni 16%, S≤0.01%, P≤0.02%, Y3O2≤0.1%, balance Fe.

[0067] (3) The preparation process is as follows: 3.1. Preparation of metal-ceramic wear-resistant surface layer powder: The prepared metal-ceramic wear-resistant surface material (1 kg in total) was placed into a ball mill with a ball-to-material ratio of 7:1, a rotation speed of 300 r / min, and a ball milling rhythm setting of 30 min forward rotation, 30 min stop, and 30 min reverse rotation. The total ball milling time was 48 h. The ball milling media consisted of 50 wt% anhydrous ethanol and 0.5 wt% PVA. The obtained powder was dried and sieved for later use to obtain metal-ceramic wear-resistant surface powder.

[0068] 3.2. Preparation of metal-ceramic transition layer powder: The prepared metal-ceramic transition layer material (1 kg in total) was placed into a ball mill with a ball-to-material ratio of 5:1, a rotation speed of 300 r / min, a ball milling rhythm setting of 30 min forward rotation, 30 min stop, and 30 min reverse rotation, and a total ball milling time of 30 h. The ball milling media consisted of 50 wt% anhydrous ethanol and 0.5 wt% PVA. The resulting powder was dried and sieved for later use to obtain the metal-ceramic transition layer powder.

[0069] 3.3. Preparation of metal underlayer powder: The prepared metal underlay material (1 kg in total) was placed into a ball mill with a ball-to-material ratio of 5:1, a rotation speed of 300 r / min, a ball milling rhythm setting of 30 min forward rotation, 30 min stop, and 30 min reverse rotation, and a total ball milling time of 30 h. The ball milling media consisted of 50 wt% anhydrous ethanol and 0.5 wt% PVA. The resulting powder was dried and sieved for later use to obtain the metal underlay powder.

[0070] 3.4. First, the metal base layer powder is loaded into the mold and pressed under 200MPa pressure for 2 minutes. Then, the metal-ceramic transition layer powder is loaded into the upper part of the mold and pressed under 100MPa pressure for 2 minutes. Finally, the dried and sieved metal-ceramic wear-resistant surface layer powder is loaded into the upper part of the mold and pressed under 100MPa pressure for 2 minutes to obtain the desired shape, thus obtaining the pressed product.

[0071] 3.5. The pressed product is placed into a matching ceramic sintering mold and sintered under vacuum (10-3 Pa) and constant pressure of 20 MPa at a sintering temperature of 1350℃. The sintering process is as follows: heating rate 7℃ / min, sintering time 2.5 hours, holding time 0.5 hours, and then cooling to room temperature with the furnace to obtain a weldable wear-resistant component. The surface hardness of the weldable wear-resistant component reaches HRC62.

[0072] 3.6. The above-mentioned weldable wear-resistant components are assembled with the hammer substrate 4 by laser welding in an assembly line to obtain wear-resistant hammers for feed crushers.

[0073] In this embodiment, the hammer blade substrate 4 is 65Mn.

[0074] A schematic diagram of the wear-resistant components and their assembly with the hammer substrate 4 is shown below. Figure 1 For reference, see the actual picture of wear-resistant hammers used in feed crushers. Figure 2 .

[0075] Different regions are pressed and assembled into the same mold using different cold-pressing parameters, and then hot-pressed to form the final wear-resistant component. The connection method is characterized by connecting the metal underlayer 1 to the hammer substrate 4 via laser welding, maintaining the metallurgical interface at the weld surface. The technical advantage of this application lies in the fact that the wear-resistant component is prepared using powder metallurgy, which significantly improves processing efficiency compared to traditional surface welding. Furthermore, the composition exhibits a clear (millimeters-level thickness) gradient in hardness, thus combining both hardness and toughness.

[0076] Comparative Example 1 The difference from Example 1 is that the metal underlayer 1 and the metal-ceramic transition layer 2 are omitted.

[0077] That is, the metal-ceramic wear-resistant surface layer 3 powder obtained in 3.1 is loaded into a mold and pressed under a pressure of 200MPa for 2 minutes. The pressed product is then loaded into a matching ceramic sintering mold and sintered under vacuum (10-3Pa) and constant pressure of 20MPa at a sintering temperature of 1350℃. The sintering process is as follows: heating rate 7℃ / min, sintering time 2.5 hours, holding time 0.5 hours, and then cooling to room temperature in the furnace. The wear-resistant components are then assembled with the hammer substrate 4 in an assembly line using laser welding to obtain the hammer.

[0078] Comparative Example 2 The difference from Example 1 is that the metal-ceramic transition layer 2 is omitted.

[0079] That is, the metal-ceramic wear-resistant surface powder obtained in 3.1 is loaded into a mold and pressed under a pressure of 200 MPa for 2 minutes. Then, the dried and sieved metal base powder is loaded into the upper part of the mold and pressed under a pressure of 100 MPa for 2 minutes to obtain the desired shape, thus obtaining the pressed product.

[0080] The pressed product is placed into a matching ceramic sintering mold and sintered under vacuum (10-3 Pa) and constant pressure of 20 MPa at a sintering temperature of 1350℃. The sintering process is as follows: heating rate 7℃ / min, sintering time 2.5 hours, holding time 0.5 hours, and then cooling to room temperature in the furnace. The above wear-resistant components are then assembled with the hammer substrate 4 in an assembly line using laser welding to obtain the hammer.

[0081] Performance testing:

[0082] Since the wear rate test mainly targets the surface of the weldable wear-resistant component, namely the metal-ceramic wear-resistant layer 3, the metal-ceramic wear-resistant layer 3 in Example 1, Comparative Example 1, and Comparative Example 2 are made of the same material, therefore the wear rate data are similar. The fracture toughness and bonding strength tests are performed on the entire hammer blade. Example 1, compared to Comparative Examples 1-2, adds a metal underlayer 1 and a metal-ceramic transition layer 2, mainly to improve fracture toughness; therefore, the fracture toughness and bonding strength data show a significant difference.

[0083] Based on the above performance test data, it can be seen that the wear-resistant hammer blade for the feed crusher in Example 1 does indeed have high hardness, good fracture toughness, and good wear resistance.

[0084] In contrast, Comparative Example 1 only retains the metal-ceramic wear-resistant surface layer 3, lacking the metal underlayer 1 and the metal-ceramic transition layer 2, resulting in the following situation: 1. The bonding strength drops sharply: There is no metal base layer 1 for metallurgical bonding, and the metal ceramic wear-resistant surface layer 3 and the hammer blade substrate 4 are only mechanically interlocked, resulting in a significant decrease in bonding strength and easy peeling.

[0085] 2. Increased stress concentration: The abrupt change between the high hardness of the metal ceramic wear-resistant surface layer 3 and the low hardness of the hammer blade substrate 4, without the buffer of a transition layer, results in a sharp drop in fracture toughness, making it prone to brittle fracture under impact.

[0086] 3. Wear resistance imbalance: Without the gradient support of the metal-ceramic transition layer 2, the ceramic phase of the metal-ceramic wear-resistant surface layer 3 is prone to breakage under impact, resulting in a shortened lifespan.

[0087] Comparative Example 2 lacks the metal-ceramic transition layer 2, while retaining the metal underlayer 1 and the metal-ceramic wear-resistant surface layer 3, resulting in the following situation: 1. Abrupt hardness gradient: The metal underlayer 1 is directly connected to the metal-ceramic wear-resistant surface layer 3 without gradient transition, resulting in decreased fracture toughness and crack resistance.

[0088] 2. Stress buffer failure: The absence of the metal-ceramic transition layer 2 leads to the direct transfer of impact energy to the metal underlayer 1, which can easily cause fatigue cracks in the hammer blade substrate 4.

[0089] 3. Wear resistance reduction: The ceramic phase gradient distribution in the metal-ceramic transition layer 2 is non-metallic, and the ceramic phase in the metal-ceramic wear-resistant surface layer 3 is easily detached under abrasive impact, resulting in reduced efficiency.

[0090] It should be understood that the application of this application is not limited to the examples above. Those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of this application.

Claims

1. A weldable wear-resistant component, characterized in that, It includes a metal underlayer (1), a metal-ceramic transition layer (2), and a metal-ceramic wear-resistant surface layer (3) that are fixedly connected in sequence; The metal-ceramic transition layer (2) comprises the following components by mass fraction: 75-95% transition layer metal component, with the remainder being transition layer ceramic component; The metal-ceramic wear-resistant surface layer (3) comprises the following components by mass fraction: 35-70% adhesive alloy powder, with the remainder being the wear-resistant surface layer ceramic component.

2. The weldable wear-resistant component according to claim 1, characterized in that, The chemical composition of the metal underlayment (1) by mass percentage is as follows: C 0.2-1.0%, B 0.001-0.005%, Cr 0.2-2.4%, Mo 0.002-0.01%, Si 0.2-1%, Mn 1-2.2%, Ti 0.02-1%, Ni 2-18%, S≤0.01%, P≤0.02%, Y3O2≤0.1%, with the balance being Fe and unavoidable impurity elements.

3. The weldable wear-resistant component according to claim 1, characterized in that, The chemical composition of the transition layer metal is as follows (mass percentage): C 0.5–1.2%, B 3–7.2%, Cr 11–17%, Si 3–4.5%, Mn 0.1–0.2%, Fe 4–8.7%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, balance Ni, and unavoidable impurity elements; The transition layer ceramic composition includes one or a mixture of two of titanium carbide powder and tungsten carbide powder.

4. The weldable wear-resistant component according to claim 1, characterized in that, The chemical composition of the adhesive alloy powder by mass percentage is as follows: C 0.5-1.2%, B 3-7.2%, Cr 11-17%, Si 3-4.5%, Mn 0.1-0.2%, Fe 4-8.7%, S≤0.01%, P≤0.01%, Y3O2≤0.1%, balance Ni, and unavoidable impurity elements; The wear-resistant surface layer ceramic composition includes one or a mixture of two of titanium carbide powder and tungsten carbide powder.

5. A method for preparing a weldable wear-resistant component based on any one of claims 1-4, characterized in that, Includes the following steps: The metal underlay material is prepared according to the required proportion of the chemical composition mass percentage of the metal underlay (1), and ball-milled to obtain metal underlay powder; The transition layer metal component is prepared according to the required mass percentage of the chemical composition of the transition layer metal component to obtain the transition layer metal component material; the transition layer metal component material and the transition layer ceramic component are mixed to obtain the metal-ceramic transition layer material; and ball milling is performed to obtain the metal-ceramic transition layer powder. The adhesive alloy powder is prepared according to the required proportion of the chemical composition by mass percentage to obtain the adhesive alloy powder; the wear-resistant surface layer ceramic component is mixed with the adhesive alloy powder to obtain the metal-ceramic wear-resistant surface layer material; ball milling is performed to obtain the metal-ceramic wear-resistant surface layer powder. The metal underlay powder is pressed to obtain the metal underlay (1); The metal-ceramic transition layer powder is pressed further to obtain the metal-ceramic transition layer (2); The metal-ceramic wear-resistant surface powder is then pressed to form the metal-ceramic wear-resistant surface layer (3), and a pressed product is obtained. The pressed product is sintered to obtain the weldable wear-resistant component.

6. The method for preparing the weldable wear-resistant component according to claim 5, characterized in that, The metal underlay powder is pressed under a pressure of 150-250MPa and kept under constant pressure for 1-5 minutes to obtain the metal underlay (1); The metal-ceramic transition layer powder is pressed under a pressure of 50-150MPa and kept under constant pressure for 1-5 minutes to obtain the metal-ceramic transition layer (2); The metal-ceramic wear-resistant surface powder is pressed under a pressure of 50-150MPa and kept under constant pressure for 1-5 minutes to form the metal-ceramic wear-resistant surface layer (3).

7. The method for preparing a weldable wear-resistant component according to claim 5, characterized in that, The pressed product is sintered under vacuum and constant pressure conditions at a temperature of 1250℃-1350℃. The sintering process is as follows: heating rate of 5-10℃ / min, sintering time of 2.5-4.5 hours, and holding time of 10-30 minutes; thus obtaining the weldable wear-resistant component.

8. The method for preparing the weldable wear-resistant component according to claim 7, characterized in that, The constant pressure is 20-40 MPa.

9. A wear-resistant hammer blade for a feed crusher, characterized in that, Includes a hammer base material (4) and a weldable wear-resistant component, wherein the side of the hammer base material (4) is fixedly connected to the side of the metal underlayer (1) of the weldable wear-resistant component away from the metal-ceramic transition layer (2); The weldable wear-resistant component is the weldable wear-resistant component according to any one of claims 1-4 or the weldable wear-resistant component prepared by the method of preparing the weldable wear-resistant component according to any one of claims 5-8.

10. A method for preparing wear-resistant hammers for a feed crusher based on the method described in claim 9, characterized in that, The hammer substrate (4) and the metal underlayer (1) of the weldable wear-resistant component are assembled by welding to obtain a wear-resistant hammer for a feed crusher.

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