Solid-liquid composite bimetallic cast particle ceramic lining plate and manufacturing method thereof

Abstract

The application discloses a kind of solid-liquid composite bimetallic melting cast particle ceramic lining plate and manufacturing method thereof, it is related to wear-resistant lining plate technical field.The wear-resistant metal matrix (1) of the lining plate working position is melted and cast with the columnar particle ceramic polymer (2) of uniform arrangement, vertical suspension, and the opening bottom plate (3) is melted and cast in the bottom of wear-resistant metal matrix (1).Particle ceramic (21) hardness is HRC65~90, polymer is columnar and regularly distributed, and does not form continuous network structure, avoid splitting matrix;The hole of opening bottom plate (3) is provided with sharp tines (32), and is metallurgically combined with high-temperature metal liquid when casting.The polymer is made of particle ceramic and high-temperature glue etc., then the polymer is suspended and fixed in the casting mold, and the wear-resistant metal liquid is cast and assisted by induction heating, and the service life is long after cooling and heat treatment.The lining plate has high wear resistance, high strength and excellent impact resistance, and is suitable for various material dropping and mill lining plate.

Description

Technical Field

[0001] This invention relates to the field of wear-resistant liner technology, specifically to a solid-liquid composite bimetallic cast ceramic liner, and also to a method for manufacturing the solid-liquid composite bimetallic cast ceramic liner. Background Technology

[0002] Material liners for hoppers / troughs in mining, metallurgy, building materials, thermal power, and chemical industries, as well as mill liners for ball mills, rod mills, and autogenous mills, are crucial components for protecting the hopper / trough shells and mill cylinders, and improving grinding efficiency. Their primary function is to protect the hopper / trough shells and mill cylinders from direct impact and friction from materials and grinding media, extending their service life. Secondly, through the use of liners of different shapes (such as corrugated and stepped shapes), energy is transferred to the materials and grinding balls / forgings / bars during the cylinder's rotation, leveraging the shape and friction of the liners. This helps to lift the materials and grinding balls / forgings / bars, imparting them with potential energy and kinetic energy for impact and grinding, thus creating a trajectory that meets the requirements of the grinding process and improving grinding performance. Furthermore, the close connection between the liners and the mill cylinder significantly enhances the rigidity of the mill cylinder, effectively preventing deformation.

[0003] In existing technologies, blanking liners and mill liners are mainly made of the following three materials: The first type of metal liner commonly uses high-manganese steel, alloy steel, wear-resistant alloy cast iron, and bimetallic composite materials. These materials struggle to balance wear resistance and impact resistance; those with good toughness have low hardness, while those with high hardness are brittle, and their high density and weight lead to high mill energy consumption. For example, high-manganese steel liners have poor wear resistance under low-impact conditions; alloy steel liners have average performance, and improving performance is costly; high-chromium alloy cast iron liners have high hardness and good wear resistance, but poor impact resistance. Furthermore, bimetallic wear-resistant composite liners have limitations such as high energy consumption and limited single-layer thickness (≥30mm), making them unsuitable for thin liners.

[0004] The second type of non-metallic lining material mainly includes rubber and ceramic. Rubber lining has low density and poor strength, and its wear resistance is insufficient under high hardness materials; ceramic lining is brittle, has poor impact resistance, and its application range is limited.

[0005] The third type of metal-cast honeycomb / mesh granular ceramic composite liner is made by bonding granular ceramic particles into a honeycomb / mesh preform using high-temperature resistant adhesive, and then pouring molten metal into it. However, the continuous, mesh-like honeycomb / mesh ceramic preform will tear the metal matrix, making it prone to brittle fracture under impact; moreover, due to the large difference in the coefficients of thermal expansion between metal and ceramic, cracks are easily generated on the surface of the casting during cooling, and these cracks propagate under impact, leading to fracture.

[0006] Chinese patent application No. 2018206328085 discloses a bimetallic wear-resistant block composed of a solid-liquid composite of low-carbon steel and high-chromium cast iron with good wear resistance. Due to the relatively small amount of molten metal and its rapid cooling rate, the wear-resistant block exhibits unbonded gaps at the bimetallic interface on its outer surface. These gaps can become future crack sources, causing the internally bonded bimetals to separate at the bonding surface. The block is fixed by the mechanical cooperation between the downward protrusion of the high-chromium cast iron and the conical hole of the low-carbon steel. It is difficult for the high-chromium cast iron and low-carbon steel to form a metallurgical bond. Under impact conditions, the high-chromium cast iron block is prone to breakage and peeling, which seriously affects the service life of the wear-resistant block. This technology suffers from the defects of bimetallic bonding technology and does not have the metal ceramic technology to improve wear resistance.

[0007] Chinese Patent Publication No. CN1962122A discloses a method for preparing a dual-liquid dual-alloy wear-resistant liner, in which both the wear-resistant layer and the substrate layer are made of bainitic steel. When using this technology to produce liners with large volume and thick plate, it is difficult to control the hardenability of the plate heat treatment, resulting in uneven thickness of the wear-resistant layer and making it difficult to balance the microstructure and properties of the wear-resistant layer and the substrate layer.

[0008] Chinese patent application number 202110776019.5 discloses a solid-liquid composite casting method for weldable bimetallic wear-resistant parts, which involves coating a boric acid layer on a low-carbon steel plate to prevent oxidation. However, it does not solve the heat problem of large-area metallurgical bonding and still relies on mechanical coordination, without involving metal ceramic technology.

[0009] Chinese patent application number 201710541579.6 discloses a ceramic / metal composite wear-resistant liner and its preparation method, which uses mechanical inlay and screw connection, and has a lower strength than metallurgically bonded composite liners.

[0010] In summary, the existing hopper / trough feed liners and mill liners suffer from problems such as complex manufacturing processes, high costs, low impact resistance, and poor wear resistance due to their material, production process, and structural design. This results in short service life, high maintenance costs, and high energy consumption, which affects production efficiency and economic benefits. Summary of the Invention

[0011] The purpose of this invention is to solve the above-mentioned problems by providing a solid-liquid composite bimetallic fused-cast granular ceramic liner that has high hardness, high wear resistance and excellent impact resistance, and can extend the service life of the liner, reduce production energy consumption and manufacturing costs.

[0012] Another object of the present invention is to provide a method for manufacturing the solid-liquid composite bimetallic fused cast ceramic liner.

[0013] The present invention discloses a solid-liquid composite bimetallic cast granular ceramic liner, wherein columnar granular ceramic aggregates 2 are uniformly arranged and vertically suspended in the wear-resistant metal matrix 1 of the working part of the liner, and an open bottom plate 3 is cast at the bottom of the wear-resistant metal matrix 1.

[0014] The aforementioned solid-liquid composite bimetallic fused cast ceramic liner, wherein the wear-resistant metal matrix 1 is made of chromium-molybdenum alloy wear-resistant cast steel, silicon-manganese alloy wear-resistant cast steel, high-chromium alloy wear-resistant cast iron, or ductile iron.

[0015] The aforementioned solid-liquid composite bimetallic cast granular ceramic liner wherein the columnar granular ceramic polymer 2 is cylindrical, square, or hexagonal.

[0016] The aforementioned solid-liquid composite bimetallic cast granular ceramic liner wherein the granular ceramic 21 is made of alumina Al2O3 ceramic, zirconium oxide ZrO2 ceramic, ZTA ceramic, silicon carbide SiC ceramic, titanium carbide TiC ceramic, or tungsten carbide WC ceramic.

[0017] The aforementioned solid-liquid composite bimetallic cast granular ceramic liner, wherein the columnar granular ceramic polymer 2 has a size of φ10~40mm and a height of 10~60mm.

[0018] The aforementioned solid-liquid composite bimetallic cast granular ceramic liner, wherein the granular ceramic 21 has a size of φ1~6mm and a hardness of HRC65~90.

[0019] The aforementioned solid-liquid composite bimetallic cast granular ceramic liner, wherein the perforated bottom plate 3 has a thickness of 2-30 mm, and the bottom plate is arc-shaped with an arc consistent with the arc of the hopper trough shell or the mill cylinder.

[0020] In the aforementioned solid-liquid composite bimetallic cast granular ceramic liner, the perforated bottom plate 3 has holes 31 with a size of φ5~50mm, a spacing of 5~30mm between holes 31, and the holes 31 are regularly distributed.

[0021] The aforementioned solid-liquid composite bimetallic fused cast ceramic liner, wherein the perforated bottom plate 3 is a rolled steel plate, the material of which is Q235, Q345, 65Mn, NM360, Hardox450 or NM500.

[0022] In the aforementioned solid-liquid composite bimetallic fused cast ceramic liner, the hole 31 in the perforated bottom plate 3 is circular, rectangular, hexagonal, or serrated, and the edge of the hole 31 is a sharp edge tooth 32.

[0023] The aforementioned solid-liquid composite bimetallic fused cast ceramic liner has bolt holes 4 for mounting connecting bolts in the wear-resistant metal substrate 1 and the perforated bottom plate 3.

[0024] The present invention discloses a method for manufacturing a solid-liquid composite bimetallic cast granular ceramic liner, comprising the following steps: (1) Select granular ceramic 21 with a size of φ1~6mm, the material of which is alumina Al2O3 ceramic, zirconium oxide ZrO2 ceramic, ZTA ceramic, silicon carbide SiC ceramic, titanium carbide TiC ceramic or tungsten carbide WC ceramic, and the hardness HRC70~90; make an EPS foam mold for granular ceramic polymer 2, the inner cavity of the mold has a size of φ10~40mm and a height of 10~60mm; place steel nail 22 with a size of φ3~10mm and a length of 20~100mm with the bottom facing down in the center of the bottom of the inner cavity of the polymer 2 mold; mix granular ceramic 21 with a size of φ1~6mm, high temperature glue, and 400~800 mesh ferrochrome alloy powder in a ratio of 10:1:1 evenly, pour it into the inner cavity of the polymer 2 mold, let it stand for 2~5 days, and then bake it at 150~300℃ for 8~24h to dehydrate it to obtain granular ceramic polymer 2 with steel nail 22 inserted; The aforementioned high-temperature adhesives are inorganic copper oxide-based high-temperature adhesives, sodium silicate high-temperature adhesives, potassium silicate high-temperature adhesives, high-temperature resistant phenolic resins, high-temperature resistant silica sols, or high-temperature resistant aluminum sols.

[0025] (2) A bottom plate 3 with evenly distributed holes 31 is cut from a Q235, Q345, NM360, NM450, or NM500 rolled steel plate with a thickness of 4-50mm. The shape of the holes 31 is circular, rectangular, hexagonal, or serrated. The diameter of the holes 31 is φ5-100mm. The distance between the holes 31 is 5-100mm. The edge of the holes 31 is a sharp edge tooth 32. The liner is an arc-shaped mill liner. After the perforated bottom plate 3 is rolled and pressed into the corresponding arc according to the shape of the mill liner drawing, it is placed at the bottom of the casting sand mold cavity of the liner; (3) The columnar granular ceramic polymer 2 with steel nails 22 inserted is suspended and fixed in the liner casting model at a distance of 5-10 mm from the working surface of the liner; (4) Prepare the alloy steel or alloy cast iron material of wear-resistant metal matrix 1 according to conventional casting process, melt it, and pour the high temperature molten metal into the mold cavity of the liner plate casting mold after reaching the casting temperature. (5) During the casting process, a medium / high frequency heating device is used to induction heat the molten metal in the casting mold cavity; (6) After the casting cools and solidifies, cut off the steel nails 22 that protrude above the working surface of the liner plate, grind and clean the sand to obtain the liner plate casting, process the liner plate casting according to the corresponding heat treatment process of wear-resistant metal material, and put it into the warehouse after shaping, correction and inspection.

[0026] Compared with the prior art, this invention has significant advantages. As can be seen from the above technical solution, the granular ceramic polymer in the liner of this invention has gaps between the granular ceramic particles. The molten wear-resistant metal matrix at high temperature can be cast into the granular ceramic polymer to obtain a metal-ceramic composite with high hardness and high strength. The cast columnar granular ceramic polymer is vertically upright and regularly distributed in the wear-resistant metal matrix. Since the hardness of the granular ceramic is as high as HRC70-90, it can greatly improve the wear resistance of the liner. The columnar granular ceramic polymer is suspended, upright and regularly distributed, and does not connect into a network structure, so it will not cut the wear-resistant metal matrix and will not reduce the impact resistance of the liner. The steel nails in the columnar granular ceramic polymer protrude above the working surface of the liner casting. During the cooling and forming process of the casting, the numerous steel nails hinder the solidification shrinkage of the wear-resistant metal matrix on the surface of the liner, balance the difference in the expansion coefficients of ceramic materials and metal materials, and eliminate the problem of easy cracking on the surface of metal-ceramic composite castings.

[0027] The bottom perforated plate of the liner of this invention is made of high-strength and high-toughness rolled steel plate. The sharp teeth along the evenly distributed hole edges are easily melted by the high-temperature metal during the casting process, which promotes the fusion of the wear-resistant metal matrix and the perforated plate, and improves the overall strength and impact resistance of the liner. Even if the wear-resistant metal matrix is ​​subjected to a large impact and cracks during use, the liner will not break as a whole because of the connection and support of the perforated plate at the bottom.

[0028] During the casting of the liner plate, a medium / high frequency induction heating device is used to heat the molten metal in the mold cavity of the casting, which strengthens the metallurgical bond between the high temperature molten metal and the perforated bottom plate, further promotes the casting penetration of the high temperature molten metal into the columnar granular ceramic polymer, and allows the molten metal to fully cover the granular ceramic.

[0029] In summary, the base plate of the liner of the present invention is a rolled steel plate with good toughness and impact resistance, and the working part is a ceramic composite material of high hardness and wear resistance fused metal particles. The steel plate and the wear-resistant metal are metallurgically bonded. Therefore, the liner of the present invention has excellent comprehensive performance of high wear resistance, high strength and impact resistance.

[0030] Specific embodiments of the present invention are given in detail in the following examples and accompanying drawings: Attached Figure Description

[0031] Figure 1-1 A schematic diagram of the structure of Embodiment 1 of the present invention; Figure 1-2 Top-view perspective view of Embodiment 1 of the present invention; Figure 1-3 A bottom-view perspective view of Embodiment 1 of the present invention; Figure 2-1 A schematic diagram of the structure of Embodiment 2 of the present invention; Figure 2-2Top-view perspective view of Embodiment 2 of the present invention; Figure 2-3 A bottom-view perspective view of Embodiment 2 of the present invention; Figure 3-1 A schematic diagram of the structure of Embodiment 3 of the present invention; Figure 3-2 Top-view perspective view of Embodiment 3 of the present invention; Figure 3-3 A bottom-view perspective view of Embodiment 3 of the present invention; Figure 4-1 A schematic diagram of the structure of Embodiment 4 of the present invention; Figure 4-2 Top-view perspective view of Embodiment 4 of the present invention; Figure 4-3 A bottom-view perspective view of Embodiment 4 of the present invention; Figure 5-1 Structural diagram of embodiment 5 of the present invention; Figure 5-2 Top-view perspective view of Embodiment 5 of the present invention; Figure 5-3 A bottom-view perspective view of Embodiment 5 of the present invention; Figure 6-1 A schematic diagram of the structure of Embodiment 6 of the present invention; Figure 6-2 Top-view perspective view of Embodiment 6 of the present invention; Figure 6-3 A bottom-view perspective view of Embodiment 6 of the present invention; Figure 7 Schematic diagram of the structure of particulate ceramic polymer 2.

[0032] Marked in the image: 1. Wear-resistant metal matrix, 2. Particulate ceramic polymer, 21. Particulate ceramic, 22. Steel nail, 3. Perforated base plate, 31. Hole, 32. Hole edge teeth, 4. Bolt hole. Detailed Implementation

[0033] The following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of the solid-liquid composite bimetallic cast granular ceramic liner proposed in this invention: Example 1: See Figure 1-1 , Figure 1-2 , Figure 1-3 A method for manufacturing a solid-liquid composite bimetallic (NM360 steel plate + ZG35SiMnB alloy steel) cast TiC particle ceramic flat liner includes the following steps: (1) Select TiC granular ceramic 21 with a size of φ3~4mm and a hardness of HRA65; make an EPS foam mold for cylindrical polymer 2 with an inner cavity size of φ20mm and a height of 40mm; place a steel nail 22 with a size of φ6mm and a length of 100mm with its bottom facing down in the center of the bottom of the inner cavity of the cylindrical polymer 2 mold; mix TiC granular ceramic 21 with a size of φ3~4mm, high temperature resistant silica sol, and 400 mesh ferrochrome alloy powder in a ratio of 10:1:1 evenly, pour it into the inner cavity of the polymer 2 mold, let it stand for 5 days, and then bake it at 200℃ for 8 hours to dehydrate it, thus obtaining polymer 2 with steel nail 22 inserted in TiC granular ceramic 21 (see Figure 7 ); (2) Cut the NM360 perforated bottom plate 3 with a thickness of 10mm into holes 31 with a diameter of φ25mm. The sharp teeth 32 along the hole edge are serrated and the spacing of the holes 31 is 10mm. The perforated bottom plate 3 is placed at the bottom of the casting sand mold cavity of the liner plate. (3) The polymer 2 with steel nails 22 inserted is suspended and fixed on the top of the working part of the liner plate in the cavity of the flat liner plate casting sand mold; (4) Prepare the composition of ZG35SiMnB alloy steel wear-resistant metal matrix 1 according to conventional casting process, melt ZG35SiMnB alloy steel, and pour the high temperature molten metal into the mold cavity of the liner casting sand mold in time after reaching the casting temperature. (5) During casting, in order to strengthen the metallurgical bond between the high-temperature molten metal and the NM360 perforated bottom plate, further promote the casting penetration of the high-temperature molten metal into the columnar granular ceramic aggregate, and allow the molten metal to fully cover the granular ceramic, a medium-frequency induction heating device is used to heat the molten metal in the mold cavity of the casting. (6) After the casting cools, the steel nails 22 that protrude above the working surface of the liner are cut off to obtain the bimetallic (NM360 steel plate + ZG35SiMnB alloy steel) fused ceramic flat liner casting. After cleaning and polishing, the solid-liquid composite bimetallic (NM360 steel plate + ZG35SiMnB alloy steel) fused ceramic flat liner casting is treated with oil quenching heat treatment process. The hardness of the 35SiMnB alloy steel wear-resistant metal matrix 1 can reach HRC45~50. After tempering treatment, the product is shaped, corrected, inspected and qualified before being put into the warehouse.

[0034] Example 2: See Figure 2-1 , Figure 2-2 , Figure 2-3 A method for manufacturing a solid-liquid composite bimetallic (NM500 steel plate + KmTBCr16 high-chromium cast iron) ZTA particle ceramic flat liner includes the following steps: (1) Select ZTA granular ceramic 21 with a size of φ2~3mm and a hardness of HRA85; make an EPS foam mold for a square columnar polymer 2 with an inner cavity size of 15mm x 15mm and a height of 30mm; place a steel nail 22 with a size of φ4mm and a length of 70mm with its bottom facing down in the center of the bottom of the inner cavity of the columnar polymer 2 mold; mix an appropriate amount of ZTA granular ceramic 21 with a size of φ2~3mm, sodium silicate high-temperature adhesive, and 500-mesh ferrochrome alloy powder in a ratio of 10:1:1 evenly, pour it into the inner cavity of the polymer 2 mold, let it stand for 5 days, and then bake it at 200℃ for 12 hours to dehydrate it to obtain ZTA granular ceramic polymer 2 with steel nail 22 inserted in the middle (see Figure 7 ); (2) Cut evenly distributed φ30mm round holes 31 into the NM500 perforated bottom plate 3 with a thickness of 8mm. The sharp teeth 32 along the hole edge are sharp convex teeth in the middle. The spacing of the holes 31 is 15mm. Place the perforated bottom plate 3 at the bottom of the casting sand mold cavity of the liner plate. (3) Insert the polymer 2 with steel nails 22 into the top of the working part of the liner plate in the cavity of the liner plate casting sand mold; (4) Prepare the composition of KmTBCr16 high chromium cast iron wear-resistant metal matrix 1 according to conventional casting process, melt KmTBCr16 high chromium cast iron, and pour the high temperature molten metal into the mold cavity of the liner casting sand mold in time when the casting temperature is reached. (5) During casting, in order to strengthen the metallurgical bond between the high-temperature molten metal and the NM500 perforated bottom plate, further promote the casting penetration of the high-temperature molten metal into the columnar granular ceramic polymer, and allow the molten metal to fully cover the granular ceramic, a high-frequency induction heating device is used to heat the molten metal in the mold cavity of the casting.

[0035] (6) After the casting has cooled, cut off the steel nails 22 that protrude above the working surface of the liner plate to obtain a solid-liquid composite bimetallic (NM500 steel plate + KmTBCr16 high chromium cast iron) ZTA ceramic liner casting with KmTBCr16 high chromium cast iron wear-resistant metal matrix 1, columnar ZTA particle ceramic polymer 2 and NM500 perforated bottom plate 3. After grinding and cleaning, use air-cooled quenching + tempering heat treatment process to harden the KmTBCr16 high chromium cast iron wear-resistant metal matrix 1 to HRC58~61. After the product is sorted, it is put into storage.

[0036] Example 3: See Figure 3-1 , Figure 3-2 , Figure 3-3 A method for manufacturing a solid-liquid composite bimetallic (Hardox 450 steel plate + medium-manganese martensitic ductile iron) cast Al2O3 granular ceramic flat liner includes the following steps: (1) Select Al2O3 granular ceramic 21 with a size of φ4~5mm and a hardness of HRA85; make an EPS foam mold for hexagonal column polymer 4, with a hexagonal side length of 14mm and a height of 40mm in the inner cavity of the mold; place a steel nail 22 with a size of φ6mm and a length of 100mm with its bottom facing down in the center of the bottom of the inner cavity of the columnar preform 2 mold; mix an appropriate amount of Al2O3 granular ceramic 21 with a size of φ4~5mm, inorganic copper oxide-based high-temperature adhesive, and 600-mesh ferrochrome alloy powder in a ratio of 10:1:1, pour the mixture into the inner cavity of the preform 2 mold, let it stand for 2~5 days, and then bake it at 250℃ for 8 hours to dehydrate it, thus obtaining Al2O3 granular ceramic polymer 2 with steel nail 22 inserted in the middle (see Figure 7 ); (2) Cut the Hardox450 perforated bottom plate 3 with a thickness of 12mm into evenly distributed circular holes 31 with a diameter of φ25mm. The sharp teeth 32 on the edge of the holes are sharp concave teeth with sharp upper and lower edges. The spacing of the holes 31 is 12mm. Place it at the bottom of the casting sand mold cavity of the mill liner. (3) Insert the Al2O3 granular ceramic polymer 2 with steel nails 22 into the top of the working part of the mill liner in the mold cavity of the mill liner casting sand mold; (4) According to the composition of medium manganese martensitic ductile iron, the wear-resistant metal matrix 1 of medium manganese martensitic ductile iron is smelted and cast into the mold cavity of the mill liner casting sand mold to obtain a solid-liquid composite bimetallic (Hardox450 steel plate + medium manganese martensitic ductile iron) Al2O3 ceramic mill liner casting with columnar Al2O3 particle ceramic polymer 2 and Hardox450 perforated bottom plate 3. (5) During casting, in order to strengthen the metallurgical bond between the high-temperature molten metal and the Hardox450 perforated bottom plate, further promote the casting penetration of the high-temperature molten metal into the columnar granular ceramic polymer, and allow the molten metal to fully cover the granular ceramic, a high-frequency induction heating device is used to heat the molten metal in the mold cavity of the casting. (6) After the casting is cooled, the steel nails 22 that protrude above the working surface of the liner are cut off. The wear-resistant metal matrix 1 of medium manganese martensitic ductile iron is hardened to HRC50-55 by heat treatment to improve the wear resistance of the mill liner matrix. The product is then sorted and put into storage.

[0037] Example 4: See Figure 4-1 , Figure 4-2 , Figure 4-3 A method for manufacturing a solid-liquid composite bimetallic (Q235 steel plate + ZG42CrMo alloy steel) cast WC particle ceramic autogenous grinding mill liner includes the following steps: (1) Select WC granular ceramic 21 with a size of φ4~6mm and a hardness of HRC72; make an EPS foam mold for an elliptical cylindrical polymer 2 with an inner cavity size of φ30mmx20mm and a height of 40mm; place a steel nail 22 with a size of φ6mm and a length of 100mm with its bottom facing down in the center of the bottom of the inner cavity of the cylindrical polymer 2 mold; mix an appropriate amount of WC granular ceramic 21 with a size of φ4~6mm, high-temperature resistant phenolic resin, and 700-mesh ferrochrome alloy powder in a ratio of 10:1:1, pour the mixture into the inner cavity of the polymer 2 mold, let it stand for 5 days, and then bake it at 260℃ for 8 hours to dehydrate it, thus obtaining polymer 2 with steel nail 22 inserted in WC granular ceramic 21 (see Figure 7 ); (2) Cut holes 31 of φ30mm in even distribution on a Q235 perforated bottom plate 3 with a thickness of 16mm. The sharp teeth 32 along the hole edge are serrated and the spacing of the holes 31 is 15mm. After rolling the perforated bottom plate 3 into an arc according to the inner arc of the self-grinding mill, place it at the bottom of the mold cavity of the liner casting sand mold. (3) Insert the polymer 2 with steel nails 22 into the top of the working part of the liner plate in the cavity of the liner plate casting sand mold; (4) Prepare the composition of ZG42CrMo alloy steel wear-resistant metal matrix 1 according to conventional casting process, melt it, and pour the high-temperature molten metal into the mold cavity of the liner casting sand mold in time after reaching the casting temperature. (5) During casting, in order to strengthen the metallurgical bond between the high-temperature molten metal and the Q235 perforated bottom plate, further promote the casting penetration of the high-temperature molten metal into the columnar granular ceramic aggregate, and allow the molten metal to fully cover the granular ceramic, a medium-frequency induction heating device is used to heat the molten metal in the mold cavity of the casting. (6) After the casting is cooled, a solid-liquid composite bimetallic (Q235 steel plate + ZG42CrMo alloy steel) WC particle ceramic liner casting is obtained. After sand removal and grinding, the (Q235 steel plate + ZG42CrMo alloy steel) WC particle ceramic mill liner casting is treated with oil quenching heat treatment process. The hardness of the ZG42CrMo alloy steel wear-resistant metal matrix 1 can reach HRC45~55. After tempering treatment, the product is put into storage.

[0038] Example 5: See Figure 5-1 , Figure 5-2 , Figure 5-3 A method for manufacturing a solid-liquid composite bimetallic (65Mn steel plate + bainitic alloy ductile iron) ZrO2 particle ceramic rod mill liner includes the following steps: (1) Select ZrO2 granular ceramic 21 with a size of φ1~3mm and a hardness of HRA85 to make an EPS foam mold for cylindrical polymer 4. The inner cavity of the mold is φ25mm and the height is 40mm. Place a steel nail 22 with a size of φ6mm and a length of 70mm with its bottom facing down in the center of the bottom of the inner cavity of the cylindrical preform 2 mold. Mix an appropriate amount of ZrO2 granular ceramic 21 with a size of φ1~3mm, high temperature aluminum sol, and 800 mesh ferrochrome alloy powder in a ratio of 10:1:1. Pour the mixture into the inner cavity of the preform 2 mold. After standing for 2~5 days, bake at 250℃ for 8 hours to dehydrate, and obtain ZrO2 granular ceramic polymer 2 with steel nail 22 inserted in the middle (see Figure 7 ); (2) Cut evenly distributed circular holes 31 with a diameter of φ20mm into the 65Mn rolled perforated bottom plate 3 with a thickness of 20mm. The sharp teeth 32 on the edge of the hole are sharp concave teeth with sharp upper and lower edges. The spacing of the holes 31 is 18mm. After rolling the perforated bottom plate 3 into an arc shape according to the inner diameter of the mill, place it at the bottom of the mold cavity of the liner casting sand mold. (3) Insert the ZrO2 particle ceramic polymer 2 with steel nails 22 into the top of the working part of the mill liner in the mold cavity of the mill liner casting sand mold; (4) Prepare the composition of the wear-resistant metal matrix 1 of bainitic alloy ductile iron according to the conventional casting process, melt the bainitic alloy ductile iron, and pour the high-temperature molten metal into the mold cavity of the rod mill liner casting sand mold when the casting temperature is reached. (5) In order to strengthen the metallurgical bond between the high-temperature molten metal and the 65Mn perforated bottom plate during casting, further promote the casting penetration of the high-temperature molten metal into the columnar granular ceramic aggregate, and allow the molten metal to fully cover the granular ceramic, a high-frequency induction heating device is used to heat the molten metal in the mold cavity of the casting. (6) A bimetallic (65Mn steel plate + bainitic alloy ductile iron) fused cast ZrO2 particle ceramic mill liner casting is obtained by fused casting columnar ZrO2 particle ceramic polymer 2 and 65Mn perforated bottom plate 3. After the casting is cooled, the steel nails 22 that are higher than the working surface of the liner are cut off. After grinding and cleaning, the hardness of the bainitic alloy ductile iron wear-resistant metal matrix 1 is treated to HRC45~52 through the corresponding heat treatment process to improve the wear resistance of the rod mill liner matrix. The product is then put into storage after finishing.

[0039] Example 6: See Figure 6-1 , Figure 6-2 , Figure 6-3 A method for manufacturing a solid-liquid composite bimetallic (Q345 steel plate + KmTBCr26MoNi high-chromium alloy cast iron) ZTA particle ceramic ball mill liner includes the following steps: (1) Select ZTA granular ceramic 21 with a size of φ2~4mm and a hardness of HRA85; make an EPS foam mold for a square columnar polymer 2 with an inner cavity size of 20mm x 20mm and a height of 40mm; place a steel nail 22 with a size of φ6mm and a length of 100mm with its bottom facing down in the center of the bottom of the inner cavity of the columnar polymer 2 mold; mix an appropriate amount of ZTA granular ceramic 21 with a size of φ2~4mm, sodium silicate high-temperature adhesive, and 500-mesh ferrochrome alloy powder in a ratio of 10:1:1, pour the mixture into the inner cavity of the polymer 2 mold, let it stand for 6 days, and then bake it at 240℃ for 12 hours to dehydrate it to obtain ZTA granular ceramic polymer 2 with a steel nail 22 inserted in the middle (see Figure 7 ); (2) Cut holes 31 of φ40mm in even distribution on the Q345 perforated bottom plate 3 with a thickness of 20mm. The sharp teeth 32 along the hole edge are sharp convex teeth in the middle. The spacing of the holes 31 is 20mm. After rolling the perforated bottom plate 3 into an arc according to the inner diameter of the mill, place it at the bottom of the casting sand mold cavity of the liner plate. (3) Insert the polymer 2 with steel nails 22 into the top of the working part of the liner plate in the cavity of the liner plate casting sand mold; (4) Prepare the composition of KmTBCr26MoNi high chromium alloy cast iron wear-resistant metal matrix 1 according to conventional process, melt KmTBCr26MoNi high chromium alloy cast iron, and pour the high temperature molten metal into the mold cavity of the liner casting sand mold in time when the casting temperature is reached. (5) In order to strengthen the metallurgical bond between the high-temperature molten metal and the Q345 perforated bottom plate during casting, further promote the casting penetration of the high-temperature molten metal into the columnar granular ceramic aggregate, and allow the molten metal to fully cover the granular ceramic, a medium-frequency induction heating device is used to heat the molten metal in the mold cavity of the casting. (6) After the casting is cooled, a solid-liquid composite bimetallic (Q345 steel plate + KmTBCr26MoNi high chromium alloy cast iron) ZTA particle ceramic liner casting is obtained by inserting columnar ZTA particle ceramic polymer 2 and Q345 perforated bottom plate 3 into the KmTBCr26MoNi high chromium alloy cast iron wear-resistant metal matrix 1. After the casting is cooled, the steel nails 22 that are higher than the working surface of the liner are cut off. After grinding and cleaning the sand, the hardness of KmTBCr26MoNi high chromium alloy cast iron wear-resistant metal matrix 1 is treated to HRC60~63 by air-cooled quenching + tempering heat treatment process. After the product is sorted, it is put into the warehouse.

[0040] The above are merely preferred embodiments of the present invention and do not impose any limitations on the present invention. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from any technical solution of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A solid-liquid composite bimetallic cast granular ceramic liner, characterized in that: The wear-resistant metal matrix (1) of the working part of the liner contains uniformly arranged, vertically suspended columnar granular ceramic aggregates (2), and the perforated bottom plate (3) is cast at the bottom of the wear-resistant metal matrix (1). The columnar granular ceramic polymer (2) is composed of granular ceramic (21) and steel nails (22) penetrating therethrough, and there are gaps between the granular ceramic (21) for high-temperature molten metal to be cast and infiltrated. The perforated bottom plate (3) has regularly distributed holes (31), and the edges of the holes (31) are provided with sharp edge teeth (32).

2. The solid-liquid composite bimetallic cast granular ceramic liner as described in claim 1, characterized in that: The wear-resistant metal matrix (1) is made of chromium-molybdenum alloy wear-resistant cast steel, silicon-manganese alloy wear-resistant cast steel, high-chromium alloy wear-resistant cast iron or alloy ductile iron wear-resistant cast iron; the columnar particle ceramic polymer (2) is cylindrical, square columnar or hexagonal columnar, with a size of φ10~40mm and a height of 10~60mm.

3. The solid-liquid composite bimetallic cast granular ceramic liner as described in claim 1, characterized in that: The material of the particulate ceramic (21) is alumina ceramic, zirconium oxide ceramic, ZTA ceramic, silicon carbide ceramic, titanium carbide ceramic or tungsten carbide ceramic, and the size of the particulate ceramic (21) is φ1~6mm and the hardness is HRC65~90.

4. The solid-liquid composite bimetallic cast granular ceramic liner as described in claim 1, characterized in that: The perforated bottom plate (3) is a rolled steel plate, the material of which is Q235, Q345, 65Mn, NM360, NM450 or NM500, and the thickness is 2 to 30 mm; the size of the hole (31) is φ5 to 50 mm, the hole spacing is 5 to 30 mm, and the shape of the hole (31) is circular, rectangular, hexagonal or serrated.

5. The solid-liquid composite bimetallic cast granular ceramic liner as described in claim 1, characterized in that: The perforated bottom plate (3) is arc-shaped, and its curvature is consistent with the curvature of the hopper trough shell or the mill cylinder; the wear-resistant metal substrate (1) and the perforated bottom plate (3) are provided with bolt holes (4) for installing connecting bolts.

6. A method for manufacturing a solid-liquid composite bimetallic fused cast granular ceramic liner, characterized in that, Includes the following steps: (1) Mix the granular ceramic (21), high-temperature adhesive and ferrochrome alloy powder evenly, pour into a columnar mold, let stand and bake to dehydrate, and obtain a columnar granular ceramic polymer (2) with steel nails (22) inserted. (2) Cut evenly distributed holes (31) into the rolled steel plate and make the hole edge sharp teeth (32) to obtain the perforated bottom plate (3). (3) The columnar granular ceramic polymer (2) is suspended and fixed in the casting model, and the polymer (2) is 5-10 mm away from the working surface of the liner plate; (4) Melt the metal liquid of the wear-resistant metal matrix (1) and pour the high-temperature metal liquid into the casting mold cavity in which the perforated bottom plate (3) and the columnar particle ceramic polymer (2) are placed; (5) After the casting cools and solidifies, cut off the steel nails (22) that protrude above the working surface of the liner plate, and clean the sand to obtain the liner plate casting; (6) Heat treatment is performed on the liner casting.

7. The method for manufacturing the solid-liquid composite bimetallic fused cast granular ceramic liner as described in claim 6, characterized in that: In step (1), the size of the granular ceramic (21) is φ1~6mm, the hardness is HRC70~90, and the material is alumina ceramic, zirconium oxide ceramic, ZTA ceramic, silicon carbide ceramic, titanium carbide ceramic or tungsten carbide ceramic; the high-temperature adhesive is inorganic copper oxide-based high-temperature adhesive, sodium silicate high-temperature adhesive, potassium silicate high-temperature adhesive, high-temperature resistant phenolic resin, high-temperature resistant silica sol or high-temperature resistant aluminum sol; the mixing mass ratio of the granular ceramic (21), high-temperature adhesive and 400~800 mesh ferrochrome alloy powder is 10:1:1; the standing time is 2~5 days, the baking temperature is 150~300℃, and the baking time is 8~24h.

8. The method for manufacturing the solid-liquid composite bimetallic fused cast granular ceramic liner as described in claim 6, characterized in that: In step (2), the rolled steel plate is made of Q235, Q345, 65Mn, NM360, Hardox450 or NM500, and has a thickness of 4 to 50 mm; the diameter of the hole (31) is φ5 to 100 mm, the hole spacing is 5 to 100 mm, and the shape of the hole (31) is circular, rectangular, hexagonal or serrated.

9. The method for manufacturing the solid-liquid composite bimetallic fused cast granular ceramic liner as described in claim 6, characterized in that: In step (2), when the liner is an arc-shaped mill liner, the perforated bottom plate (3) is rolled out according to the shape of the mill liner drawing and then placed at the bottom of the casting mold cavity; in step (4), the material of the wear-resistant metal substrate (1) is alloy steel or alloy cast iron.

10. The method for manufacturing the solid-liquid composite bimetallic fused cast granular ceramic liner as described in claim 6, characterized in that: In step (4), during the casting process, a medium-frequency or high-frequency induction heating device is used to induction heat the molten metal in the casting mold cavity.

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