Vehicle-mounted new energy TMR auger surfacing structure and process

Abstract

The application discloses a kind of vehicle-mounted new energy TMR auger surfacing structure and process, it is related to the manufacturing technology field of livestock machinery, including: auger matrix, buffer corrosion-proof layer on the outer edge wear-resistant area of spiral blade of the auger matrix and hard antifriction wear-resistant layer on the outer surface of the buffer corrosion-proof layer;The buffer corrosion-proof layer is high-chromium nickel-based alloy layer;The hard antifriction wear-resistant layer is the high-chromium cast iron composite layer containing coarse tungsten carbide particles;The hard antifriction wear-resistant layer is discontinuous fish scale array distribution.The application is designed by toughness corrosion-proof buffer layer and high-hardness wear-resistant surface layer compound, and adopts discontinuous fish scale array surfacing process, realizes the significant improvement of comprehensive performance, and the wear-resistant surface layer of coarse tungsten carbide and high-chromium cast iron constitutes high hardness, can absorb new energy drive system instantaneous impact and hard foreign matter impact energy, avoid hard wear-resistant layer collapse and fall off.

Description

Technical Field

[0001] This invention relates to the field of livestock machinery manufacturing technology, specifically to a vehicle-mounted new energy TMR auger welding structure and process. Background Technology

[0002] Total Mixed Ration (TMR) mixers are key equipment in large-scale livestock farming for mixing silage, concentrates, hay, straw, and additives. With the rapid development of large-scale ranches, large-capacity vehicle-mounted new energy TMR mixers of 30 cubic meters or more are widely used. Their auger blades operate under conditions of high load, strong wear, acid corrosion, and instantaneous impact coupling: a single load can reach several tons of material, and the outer edge of the blades is in continuous contact with hay, straw, silage, sand, and hard impurities, resulting in severe abrasive wear; silage fermentation produces organic acids such as lactic acid and acetic acid, making the working environment weakly acidic or even locally strongly acidic; new energy electric drive or electro-hydraulic hybrid drive systems have fast start-up response and high instantaneous torque, and the blades are easily subjected to sudden impact loads from compacted hay, lumpy materials, or hard foreign objects; at the same time, the large-capacity auger diameter and long blade helix length, combined with the high heat input and residual stress concentration of traditional continuous full-coverage welding, easily cause blade warping, helix shaft eccentricity, and decreased dynamic balance performance, affecting the operational stability and service life of the equipment.

[0003] Existing wear-resistant strengthening technologies for augers mainly include welding of ordinary wear-resistant plates, single-layer high-chromium cast iron surfacing, and tungsten carbide particle surfacing, but they generally have obvious defects: there is a lack of a tough transition layer between the wear-resistant layer and the substrate, resulting in insufficient impact resistance; the high-hardness surfacing layer has poor acid resistance and is prone to pitting corrosion, intergranular corrosion, and corrosion fatigue cracks in the acidic environment of silage, leading to cracking and peeling of the surfacing layer; continuous large-area surfacing has high heat input, making it difficult to control the welding deformation of large-sized blades; the surfacing layer has a simple structure and cannot utilize the material to form a self-protection mechanism; in particular, it is difficult to adapt to the high instantaneous torque conditions of new energy drive systems, and the wear-resistant layer is prone to peeling and fatigue damage, resulting in a short overall service life and high maintenance costs. Summary of the Invention

[0004] To address the problems in related technologies, this invention proposes a welding structure and process for a vehicle-mounted new energy TMR auger. Through a composite design of a tough anti-corrosion buffer layer, a high-hardness wear-resistant surface layer, and a discontinuous biomimetic fish scale array, it solves the technical problems of easy cracking and peeling of the wear-resistant layer, large welding deformation, and short service life of the auger blades under high load, strong wear, acid corrosion, and instantaneous impact conditions of new energy vehicles.

[0005] The technical solution of this invention is implemented as follows:

[0006] One aspect of the present invention:

[0007] A vehicle-mounted new energy TMR auger weld overlay structure includes: an auger substrate, a buffer anti-corrosion layer disposed on the wear-resistant area of ​​the outer edge of the spiral blade of the auger substrate, and a hard friction-reducing and wear-resistant layer disposed on the outer surface of the buffer anti-corrosion layer;

[0008] The hard friction-reducing and wear-resistant layer is distributed in a discontinuous fish-scale array, and gaps are provided between adjacent hard friction-reducing and wear-resistant layer units to accommodate fine materials and form a self-built material layer.

[0009] Furthermore, the buffer anti-corrosion layer is a high-chromium nickel-based alloy layer;

[0010] The hard friction-reducing and wear-resistant layer is a high-chromium cast iron composite layer containing coarse-grained tungsten carbide particles;

[0011] Furthermore, the wear-resistant area on the outer edge of the spiral blade is a region extending inward from the outer edge of the spiral blade by 30mm-80mm.

[0012] Furthermore, the buffer anti-corrosion layer is made of Cr25Ni13 type high chromium nickel-based alloy material with a thickness of 0.8mm-3.0mm.

[0013] Furthermore, the mass percentage of coarse-grained tungsten carbide particles in the hard friction-reducing and wear-resistant layer is 15% to 25%.

[0014] Furthermore, the units of the hard friction-reducing and wear-resistant layer are crescent-shaped, scale-shaped, arc-shaped, or approximately elliptical arc-shaped weld bead units.

[0015] Furthermore, the gap between adjacent hard friction-reducing and wear-resistant layer units is 3mm-5mm.

[0016] Another aspect of the present invention:

[0017] A welding process for a vehicle-mounted new energy TMR auger, used to prepare the above-mentioned vehicle-mounted new energy TMR auger welding structure, includes the following steps:

[0018] Clean the wear-resistant area on the outer edge of the auger blades beforehand;

[0019] Preheat the area to be welded in sections;

[0020] A high-chromium nickel-based alloy buffer and anti-corrosion layer is welded onto the wear-resistant area of ​​the outer edge of the blade.

[0021] A high-chromium cast iron composite material containing coarse-grained tungsten carbide particles is overlaid on the outer surface of the buffer anti-corrosion layer to form a hard, friction-reducing, and wear-resistant layer with a discontinuous fish-scale array.

[0022] During the welding process, a rotating auger is used to drive the auger to rotate, and a symmetrical welding method is used to reduce welding deformation.

[0023] The buffer anti-corrosion layer and / or hard friction-reducing and wear-resistant layer are prepared by plasma arc cladding process.

[0024] During or after the welding process, mechanical impact, mechanical vibration, or ultrasonic impact is applied to the weld overlay area to reduce residual welding stress.

[0025] Among them, through zoned preheating, symmetrical repair welding and mechanical impact treatment during welding, the deformation of the large-capacity auger blades after welding is controlled within ±2mm.

[0026] The beneficial effects of this invention are:

[0027] This invention achieves a significant improvement in overall performance through a composite design of a tough, corrosion-resistant buffer layer and a high-hardness, wear-resistant surface layer, using a discontinuous fish-scale array welding process. The wear-resistant surface layer, composed of coarse-grained tungsten carbide and high-chromium cast iron, has high hardness, extending its wear life by 2-3 times compared to traditional single-layer welding. The high-chromium-nickel-based buffer layer effectively resists organic acid corrosion in silage, inhibiting pitting, intergranular corrosion, and fatigue cracking. The buffer layer possesses good ductility and toughness, capable of absorbing the instantaneous impact energy of new energy drive systems and the impact energy of hard foreign objects, preventing hard... The wear-resistant layer cracks and falls off; the discontinuous fish-scale array significantly reduces welding heat input. Combined with process control of zoned preheating, symmetrical repair welding, and welding impact, the deformation of large-size auger blades can be controlled within ±2mm; the biomimetic array structure and the self-built material layer formed in the gaps reduce direct friction between metal and materials, effectively reducing operating resistance and energy consumption, adapting to the range requirements of new energy vehicle equipment, significantly extending the service life of the wear-resistant layer, reducing the frequency of blade replacement, shortening downtime for maintenance, and further reducing the overall operating cost of the equipment. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of a vehicle-mounted new energy TMR auger weld overlay structure according to an embodiment of the present invention;

[0030] Figure 2 This is a schematic diagram of a welding process for a vehicle-mounted new energy TMR auger according to an embodiment of the present invention. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0032] Example 1

[0033] According to an embodiment of the present invention, a vehicle-mounted new energy TMR auger weld overlay structure is provided.

[0034] like Figure 1 As shown, the vehicle-mounted new energy TMR auger welding structure according to an embodiment of the present invention includes an auger substrate 1, a buffer anti-corrosion layer 2, and a hard friction-reducing and wear-resistant layer 3.

[0035] The auger base 1 includes a spiral shaft and spiral blades fixed to the outer periphery of the spiral shaft, with the outer edge of the spiral blades being a wear area;

[0036] The buffer and anti-corrosion layer 2 is set in the wear-resistant area of ​​the outer edge of the spiral blade and is made of high chromium nickel-based alloy, which has both acid corrosion resistance and impact buffering capacity.

[0037] The hard friction-reducing and wear-resistant layer 3 is disposed on the outer surface of the buffer and anti-corrosion layer 2 and is made of high-chromium cast iron composite material containing coarse-grained tungsten carbide particles;

[0038] The hard friction-reducing and wear-resistant layer 3 is distributed in a discontinuous fish-scale array, with gaps 4 between adjacent units, forming a self-built material layer space that can accommodate small feed particles.

[0039] In this technical solution, the wear-resistant area on the outer edge of the spiral blade extends from the outer edge inward for 30mm to 80mm, preferably within a range of 50mm.

[0040] The thickness of the buffer anti-corrosion layer 2 is 0.8mm to 3.0mm, preferably 1.2mm to 2.0mm; the material is a Cr-Ni austenitic high chromium nickel-based alloy, preferably Cr25Ni13 alloy.

[0041] The thickness of the hard friction-reducing and wear-resistant layer 3 is 2.0 mm to 6.0 mm, preferably 3.0 mm to 4.5 mm; the mass fraction of coarse-grained tungsten carbide particles is 15% to 25%, and the particle size is 0.3 mm to 2.5 mm, preferably 0.6 mm to 1.5 mm.

[0042] Among them, the three units of the hard friction-reducing and wear-resistant layer are crescent-shaped, scale-shaped, arc-shaped or elliptical arc-shaped, and are arranged alternately along the outer edge of the blade; the gap between adjacent units is 43mm to 5mm.

[0043] The fish-scale array unit has a width of 8mm to 20mm and a length of 20mm to 60mm; the arc-shaped protrusions are adapted to the relative sliding direction of the material; the material-facing side is arranged with high density and the material-backing side is arranged with low density.

[0044] With the help of this embodiment, a composite wear-resistant layer structure of a 30 cubic meter vehicle-mounted new energy dual auger TMR mixer is provided, including a auger shaft and auger blades; the wear-resistant area is within 50 mm of the outer edge of the blades.

[0045] The second buffer anti-corrosion layer is a Cr25Ni13 high-chromium nickel-based alloy with a thickness of 1.5mm;

[0046] The hard friction-reducing and wear-resistant layer 3 contains 20% coarse-grained tungsten carbide particles, which are high-chromium cast iron composite materials with a particle size of 1.0 mm and a thickness of 3.5 mm.

[0047] The rigid layer unit adopts a crescent shape, 12mm wide and 35mm long, and is arranged in an alternating manner with a 4mm gap between adjacent units;

[0048] Specifically, during operation, the finely crushed silage enters gap 4 to form a self-built material layer, reducing direct metal wear.

[0049] Example 2

[0050] According to an embodiment of the present invention, a welding process for a vehicle-mounted new energy TMR auger is provided for preparing the welding process of Embodiment 1.

[0051] like Figure 1 As shown, the on-board new energy TMR auger welding process according to an embodiment of the present invention includes the following steps:

[0052] Pre-treatment of the substrate is carried out, the wear-resistant area on the outer edge of the blade is cleaned, oil, scale, rust, cracks and loose metal layers are removed, and the blade is polished until the metal luster is exposed. If necessary, the blade is reshaped during the process to conform to the spiral curve.

[0053] Perform zoning and marking, designating the outer edge 50mm inward as the wear-resistant area, dividing the welding zones according to the rotation direction, material flow direction, and wear level, marking the position of the fish scale weld unit, and leaving a 3mm to 5mm gap 4;

[0054] Preheating is carried out in zones using flame, resistance, induction, or hot air preheating, with temperatures ranging from 120℃ to 250℃; low-alloy / high-manganese steel substrates are preheated with low input and slow heating to prevent thermal cracking.

[0055] The buffer anti-corrosion layer 2 is prepared by plasma arc cladding, laser cladding, flux-cored wire welding or gas shielded welding; plasma arc cladding is preferred. The interlayer temperature is controlled and the slag is removed by light grinding after completion.

[0056] Prepare a hard friction-reducing and wear-resistant layer 3, and deposit a high-chromium cast iron composite material containing coarse-grained tungsten carbide particles on the surface of the buffer and anti-corrosion layer 2. Plasma arc cladding is preferred to disperse the particles and form a discontinuous fish-scale array, leaving a gap of 3mm to 5mm 4.

[0057] In addition, specifically, the auger is fixed to a special rotating jig and rotates at a uniform speed / intermittently. Symmetrical repair welding and axial skip welding are used, and mechanical vibration, impact or ultrasonic impact is applied during welding to release residual stress. After welding, slow cooling is performed, and if necessary, local tempering, vibration aging or low-temperature stress relief are carried out. Dimensions, coaxiality, warpage, surface defects, etc. are checked to meet design requirements.

[0058] Example 3

[0059] According to an embodiment of the present invention, based on Embodiment 1, a vehicle-mounted new energy TMR auger weld overlay structure is provided to adapt to low-impact and high-toughness working conditions.

[0060] The vehicle-mounted new energy TMR auger welding structure according to the present invention has a hard layer tungsten carbide particle content of 15% based on the first embodiment. It is suitable for working conditions with less grass and sand particles and large impact loads, and has better impact resistance and crack resistance.

[0061] Example 4

[0062] According to an embodiment of the present invention, based on Embodiment 1, a vehicle-mounted new energy TMR auger welding structure is provided to adapt to high wear conditions.

[0063] The vehicle-mounted new energy TMR auger welding structure according to an embodiment of the present invention, based on embodiment one, has a tungsten carbide particle content of 25% in its hard layer, making it suitable for working conditions with many sand particles and strong abrasive wear, and has higher hardness and better wear resistance.

[0064] Using the above embodiments, the comprehensive performance of the composite wear-resistant layer structure of the present invention was verified. An existing non-welding strengthening process, that is, directly using high manganese steel or wear-resistant steel substrate, was selected as a comparative example and its performance was compared with that of Embodiment 1, Embodiment 3 and Embodiment 4 of the present invention. The comparison results are shown in Table 1.

[0065] Table 1 Comparison of Abrasion Resistance Performance

[0066] Comparison Projects unit Existing technology Example 1 Example 3 Example 4 WC content in hard layer wt% 0 20 15 25 Surface hardness (HRC) HRC 28～35 58～64 55～60 62～68 Abrasive wear relative life times 1.0 (Baseline) 2.4～2.8 2.0～2.3 2.8～3.2 Acid corrosion rate (5% lactic acid, 48h) <![CDATA[mg / (cm 2 ·h)]]> 0.18～0.25 0.03～0.06 0.03～0.06 0.03～0.06 Critical energy for impact spalling J 8～12 28～35 35～42 22～28 Blade deformation after welding mm 0 (No welding) ≤±1.8 ≤±1.7 ≤±1.9 Increased operating energy consumption (relative to no weld overlay) % 0 (benchmark) -6～-10 -5～-8 -7～-11 Average continuous working life h 800～1200 2000～2800 1800～2200 2500～3200

[0067] As shown in Table 1, compared with existing high-manganese steel / wear-resistant steel substrates without weld overlay, the composite wear-resistant layer structures prepared in Examples 1, 3, and 4 of this invention achieve significant improvements in all key performance aspects. The surface hardness increases from 28–35 HRC of the substrate to 55–68 HRC, the relative life of abrasive wear is increased by 2.0–3.2 times, and the average continuous working life can reach 1800–3200 hours. The high-chromium-nickel-based buffer layer reduces the acid corrosion rate to 0.03–0.06 mg / (cm³). 2 •h), only 1 / 4 to 1 / 5 of the substrate, effectively resisting the corrosion of silage organic acids; the critical energy for impact spalling is increased to 22 to 42 J, among which, Example 3 has the best toughness and the strongest impact resistance, Example 4 has the highest hardness and the best wear resistance, and Example 1 takes into account the comprehensive advantages of wear resistance and impact resistance; the discontinuous fish scale array overlay welding process controls the blade deformation within ±2 mm, meeting the dynamic balance requirements of large-volume augers; at the same time, the self-built material layer structure reduces the running resistance, and the energy consumption is reduced by 5% to 11% compared with the substrate without overlay welding, which is suitable for the range requirements of new energy vehicle equipment. It comprehensively solves the technical pain points of existing auger blades such as poor wear resistance, easy corrosion, weak impact resistance, large welding deformation and high energy consumption, and has significant engineering value and economic benefits.

[0068] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Those skilled in the art, upon considering the disclosure in the specification and embodiments, will readily conceive of other embodiments of this disclosure. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the claims.

[0069] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims.

Claims

1. A vehicle-mounted new energy TMR auger weld overlay structure, comprising: The auger substrate (1) is characterized in that it further includes a buffer anti-corrosion layer (2) disposed in the wear-resistant area of ​​the outer edge of the spiral blade of the auger substrate (1), and a hard friction-reducing and wear-resistant layer (3) disposed on the outer surface of the buffer anti-corrosion layer (2). The hard friction-reducing and wear-resistant layer (3) is distributed in a discontinuous fish-scale array, and gaps (4) are provided between adjacent hard friction-reducing and wear-resistant layer (3) units to accommodate fine materials and form a self-built material layer.

2. The vehicle-mounted new energy TMR auger welding structure according to claim 1, characterized in that, The buffer anti-corrosion layer (2) is a high chromium nickel-based alloy layer; the hard friction-reducing and wear-resistant layer (3) is a high chromium cast iron composite layer containing coarse-grained tungsten carbide particles.

3. The vehicle-mounted new energy TMR auger welding structure according to claim 2, characterized in that, The wear-resistant area on the outer edge of the spiral blade is a region extending 30mm-80mm inward from the outer edge of the spiral blade.

4. The vehicle-mounted new energy TMR auger welding structure according to claim 3, characterized in that, The buffer anti-corrosion layer (2) is made of Cr25Ni13 type high chromium nickel-based alloy material with a thickness of 0.8mm-3.0mm.

5. The vehicle-mounted new energy TMR auger welding structure according to claim 4, characterized in that, The mass percentage of coarse-grained tungsten carbide particles in the hard friction-reducing and wear-resistant layer (3) is 15% to 25%.

6. The vehicle-mounted new energy TMR auger weld overlay structure according to claim 1, characterized in that, The hard friction-reducing and wear-resistant layer (3) consists of crescent-shaped, scale-shaped, arc-shaped, or approximately elliptical arc-shaped weld bead units.

7. The vehicle-mounted new energy TMR auger weld overlay structure according to claim 6, characterized in that, The gap (4) between adjacent hard friction-reducing and wear-resistant layer (3) units is 3mm-5mm.

8. A welding process for a vehicle-mounted new energy TMR auger, used to prepare the vehicle-mounted new energy TMR auger welding structure according to any one of claims 1-7, characterized in that, Includes the following steps: Clean the wear-resistant area on the outer edge of the auger blades beforehand; Preheat the area to be welded in sections; A high-chromium nickel-based alloy buffer and anti-corrosion layer is welded onto the wear-resistant area of ​​the outer edge of the blade (2); A high-chromium cast iron composite material containing coarse-grained tungsten carbide particles is overlaid on the outer surface of the buffer anti-corrosion layer (2) to form a hard friction-reducing and wear-resistant layer (3) with a discontinuous fish-scale array. During the welding process, a rotating auger is used to drive the auger to rotate, and a symmetrical welding method is used to reduce welding deformation.

9. The on-board new energy TMR auger welding process according to claim 8, characterized in that, The buffer anti-corrosion layer (2) and / or hard friction-reducing and wear-resistant layer (3) are prepared by plasma arc cladding process.

10. The on-board new energy TMR auger welding process according to claim 8, characterized in that, During or after the welding process, mechanical impact, mechanical vibration, or ultrasonic impact are applied to the weld overlay area to reduce residual welding stress.

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