Wear-resistant liner and method for manufacturing wear-resistant liner

Abstract

To provide a wear-resistant liner which is constituted of a wear-resistant reinforcing material made of ceramics, cemented carbide or the like and a matrix alloy composed of a wear-resistant alloy and is improved in wear resistance while suppressing the cracks of the matrix of the wear-resistant liner in a manufacturing process.SOLUTION: By using the alloy to be the matrix on the liner surface side as a cast-formed plate material (for example, a steel plate), by disposing the reinforcing material and the cast-formed plate material in the liner case, and performing the HIP treatment, not only the occurrence of cracks in the matrix can be suppressed, but also the width of the matrix can be made thinner than before, and the area ratio of the wear-resistant reinforcing material on the surface can be increased, so that the wear resistance is also improved.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a wear liner and a method for manufacturing the wear liner. [Background technology]

[0002] In various industries that handle powders, ores, and other materials, wear and tear can cause equipment damage during transportation and storage, eventually causing the equipment to stop functioning and require replacement. Frequent replacement increases downtime and reduces productivity. To prevent this, wear-resistant liners are placed in areas prone to wear to slow the progression of wear and protect the equipment.

[0003] For example, the rotating chutes used to charge steel raw materials such as coke and iron ore into blast furnaces in steel mills are subjected to extremely large impacts and wear due to the collisions and sliding of the steel raw materials. For this reason, wear-resistant liners are installed to protect the chute surface.

[0004] Wear-resistant liners are often made from wear-resistant alloys (such as wear-resistant steel, high-Cr steel, etc.). In recent years, to enhance wear resistance, wear-resistant liners have been proposed that combine wear-resistant metals with wear-resistant reinforcement materials made from ceramics (Si3N4, SiC, Al2O3, etc.) or cemented carbide, which have a high wear-resistant effect.

[0005] For example, Patent Document 1 proposes a wear-resistant liner in which a wear-resistant reinforcement made of silicon nitride ceramic is cast-in and fixed with a high Cr alloy as a matrix so that the reinforcement is exposed on the surface.

[0006] Patent Document 2 proposes a cast composite material in which the wear-resistant material is a cemented carbide containing tungsten carbide as the main component, and the base material is high-chromium cast iron.

[0007] Patent Document 3 proposes a wear-resistant liner in which a ceramic wear-resistant reinforcement is formed into a truncated cone shape and cast into a wear-resistant alloy that serves as a matrix, in order to prevent the ceramic wear-resistant reinforcement from falling off.

[0008] Patent Document 4 proposes that in order to suppress the occurrence of cracks during the manufacturing process of a wear-resistant liner, the matrix alloy be formed into multiple layers, with the surface being made of a wear-resistant alloy and at least one of the other layers being made of mild steel. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-58155 [Patent Document 2] Japanese Patent Application Laid-Open No. 2009-6347 [Patent Document 3] Japanese Patent Publication No. 2020-180343 [Patent Document 4] Japanese Patent Application Publication No. 2023-58289 Summary of the Invention [Problem to be solved by the invention]

[0010] As in Patent Documents 1 to 3, when a wear-resistant reinforcement material such as a ceramic or cemented carbide is cast into a wear-resistant alloy, it is manufactured by casting or hot isostatic pressing (HIP). However, due to the difference in thermal expansion coefficient between the ceramic or cemented carbide and the matrix alloy, thermal stress occurs during cooling, which can easily cause cracks in the matrix alloy. Such cracks significantly reduce impact resistance, leading not only to damage to the liner itself but also to accelerated wear of the liner, shortening its lifespan as a wear-resistant liner. Furthermore, because microcracks are difficult to detect even during inspection, they can be installed in equipment without being noticed, which not only shortens the lifespan of the wear-resistant liner but can also cause equipment failure.

[0011] In Patent Document 4, thermal stress is absorbed by forming a matrix alloy into multiple layers, thereby suppressing the occurrence of cracks. However, Patent Document 4 mainly addresses thermal stress in the thickness direction of the liner, and there is room for improvement in thermal stress in the in-plane direction of the liner surface, especially when applied to a wear-resistant liner with a large area. Patent Document 4 proposes constructing a small liner assembly consisting of multiple liners and arranging these liner assemblies to construct a large-area wear-resistant liner for application to large-area actual equipment. In Patent Document 4, when manufacturing the matrix alloy, powdered raw alloy is used at least in the portion that will become the surface layer of the matrix, and the raw alloy is arranged around the wear-resistant reinforcement and then matrix alloyed by HIP treatment. However, the inventors have found that with this manufacturing method, the stress state of the finished matrix alloy changes depending on the location of the raw material arrangement in the in-plane direction, resulting in the generation of voids derived from the powder in the finished matrix alloy. These voids are prone to cracking, particularly in the in-plane direction of the liner surface, due to the thermal stress generated during HIP treatment.

[0012] From the above, when considering stable production of wear-resistant liners composed of wear-resistant reinforcements and an alloy matrix, there is room for improvement in preventing cracking due to in-plane thermal stress (in-plane thermal stress) on the liner surface during the manufacturing process. Increasing the matrix width to alleviate this in-plane thermal stress sacrifices wear resistance. On the other hand, increasing the area ratio of the wear-resistant reinforcement on the liner surface is effective for improving wear resistance. However, this would result in a thinner matrix. During the HIP manufacturing process, when the powdered raw alloy is sintered or partially melted to form the matrix, adjacent reinforcements sandwiched between the matrix may come into contact and break, or the matrix may weaken the restraining force of the wear-resistant reinforcement, making the wear-resistant reinforcement more likely to fall out of the wear-resistant liner during use.

[0013] In order to solve these problems, the present invention aims to provide a wear-resistant liner that is made of a wear-resistant reinforcement material such as ceramics or cemented carbide and an alloy matrix, and that has improved wear resistance while suppressing cracking of the matrix of the wear-resistant liner during manufacturing and use, compared to conventional wear-resistant liner that is manufactured by HIP molding using powder raw alloy at least in the surface layer side of the matrix. [Means for solving the problem]

[0014] In order to solve the above problems, the present inventors have conducted extensive research and development and have obtained the following findings. In the following description, the surface of the abrasion-resistant liner that requires abrasion resistance because powder or the like collides and slides against it is referred to as the front surface, and the opposite surface is referred to as the back surface.

[0015] (a) When the manufacturing process of a wear-resistant liner (hereinafter referred to as "liner") was examined, in which a wear-resistant reinforcement (hereinafter referred to as "reinforcement") made of ceramics, cemented carbide, or the like was placed in a matrix made of an alloy containing a wear-resistant alloy, it was found in Patent Document 4 that, whether by casting or hot pressing such as HIP, the shrinkage of the reinforcement, such as ceramics or cemented carbide, during the cooling process was small, while the shrinkage of the matrix was large, resulting in tensile residual stress in the matrix, which was the cause of cracks. In particular, when HIP treatment was performed using alloy powder in the matrix, it was found that the shrinkage that occurred when the powder was compressed also added, further increasing the tensile residual stress in the matrix.

[0016] Furthermore, it was found that when the size of the liner, especially the surface area of ​​the liner, is increased, the stress generated in the in-plane direction of the liner surface (direction parallel to the liner surface) increases due to the shrinkage caused by powder compression during HIP processing and the shrinkage of the matrix during the cooling process after HIP processing. The generated stress is thought to concentrate in weak parts of the liner, where cracks occur in the matrix.

[0017] (stomach) Increasing the filling rate is an effective way to reduce the shrinkage of the alloy powder that forms the matrix, but there are limits to the filling rate depending on the liner shape, the arrangement of the reinforcing materials, and even the width of the matrix (the distance between adjacent reinforcing materials).Furthermore, there is also the issue of non-uniformity in the filling rate within the liner, making it not easy to uniformly increase the filling rate of the alloy powder.

[0018] (cormorant) In addition, to improve wear resistance, it is also desirable to increase the area ratio of the reinforcement on the liner surface. In this case, increasing the area ratio of the reinforcement requires reducing the area ratio of the matrix, i.e., narrowing the matrix width (the distance between adjacent reinforcements). Narrowing the matrix width not only worsens the packing of the alloy powder, further increasing the powder compression ratio during HIP processing, but also raising concerns about the possibility of adjacent reinforcements coming into contact and breaking during HIP processing.

[0019] (workman) Therefore, instead of using alloy powder, we came up with the idea of ​​using a plate material made by casting the alloy and then processing it into a shape (an alloy plate made by melting the alloy, solidifying it, casting it, and processing it into a plate shape; for example, a steel plate; hereafter referred to as "cast-formed plate material"), which would have no voids and could be applied to the matrix, and so we proceeded with development. Since cast-molded plates have no voids, shrinkage during HIP treatment can be minimized, and as a result, it was confirmed that matrix cracking can be suppressed. Furthermore, it was found that the matrix area ratio on the liner surface can be reduced by reducing the thickness of cast-molded plates. Furthermore, it was found that the positioning of reinforcement materials during encapsulation for HIP treatment is improved, and adjacent reinforcement materials do not come into contact during HIP treatment, suppressing reinforcement damage.

[0020] The present invention was made based on the above findings, and the gist of the present invention is as follows.

[0021] [1] A wear liner having a plurality of wear-resistant reinforcements disposed in a matrix of one or more alloys, 1. A wear-resistant liner, wherein at least a surface side of the wear-resistant liner in the matrix surrounding the wear-resistant reinforcement is made of a cast plate material. [2] The wear-resistant liner according to the above [1], wherein the cast plate material on the surface side of the wear-resistant liner in the matrix is ​​one or more of a high Cr alloy, a high-speed steel, and a wear-resistant steel. [3] The wear-resistant liner according to [2] above, wherein the matrix is ​​made of stainless steel or mild steel except for the portion that will be on the surface side of the wear-resistant liner. [4] The abrasion liner according to any one of the above [1] to [3], wherein the area ratio of the abrasion resistant reinforcement on the surface of the abrasion liner is 65% or more. [5] The wear-resistant liner according to any one of the above [1] to [4], wherein the width of the matrix is ​​3.0 mm or more. [6] The wear-resistant liner according to any one of the above [1] to [5], wherein the wear-resistant reinforcement is one or more of Si3N4, SiC, and Al2O3. [7] The wear-resistant liner according to any one of the above [1] to [6], wherein the wear-resistant reinforcement is a polygonal column. [8] The wear-resistant liner according to [7], wherein the polygonal prism is a cube or a rectangular parallelepiped. [9] A method for producing the abrasion-resistant liner according to any one of the above [1] to [8], a preparation step of preparing a cast plate material by casting at least a liner case, one or more types of wear-resistant reinforcement material, and one or more types of alloy and then forming the cast plate material into a plate shape; an encapsulating step including disposing a plurality of the wear-resistant reinforcements and the cast plate material that forms a matrix around the wear-resistant reinforcements inside the liner case so as to contact the surface of the liner; A method for manufacturing a wear-resistant liner, comprising a HIP step of HIP-treating the liner case in which a plurality of the wear-resistant reinforcements and the cast plate material are arranged.

[10] The method for manufacturing a wear-resistant liner according to the above [9], wherein in the encapsulating step, the cast formed plate material on the surface side of the wear-resistant liner in the matrix is ​​made of one or more of a high Cr alloy, a high-speed steel, and a wear-resistant steel.

[11] The method for manufacturing a wear-resistant liner according to the above [9] or

[10] further comprises, after the step of performing the HIP treatment, a processing step of machining the liner case after the HIP treatment. [Effects of the Invention]

[0022] The present invention provides a wear-resistant liner composed of a matrix of an alloy and a wear-resistant reinforcement made of ceramics, cemented carbide, or the like. Compared to conventional wear-resistant liners manufactured by HIP molding using powdered raw alloys at least in the surface layer of the matrix, it is possible to improve the wear resistance of the wear-resistant liner while suppressing matrix cracking during manufacturing and use. Furthermore, it is possible to specify a higher area ratio of the wear-resistant reinforcement on the liner surface than conventional wear-resistant liners. This results in improved wear resistance and a longer life for the wear-resistant liner. Furthermore, because cracking in the matrix is ​​suppressed, it is possible to manufacture wear-resistant liners with a larger surface area than conventional wear-resistant liners. [Brief explanation of the drawings]

[0023] [Figure 1] 1 is a conceptual diagram showing an example of an abrasion liner according to the present invention. [Figure 2] 2(a) is a conceptual diagram of the liner surface of the wear-resistant liner of FIG. 1 viewed from vertically above, and FIG. 2(b) is a conceptual diagram showing a vertical cross section of the liner surface. [Figure 3]The state of the wear-resistant liner in Figure 1 before HIP treatment is shown in Figure 3(a) where the liner surface is viewed from vertically above, and in Figure 3(b) where a vertical cross section of the liner surface is shown. [Figure 4] FIG. 10 is an explanatory diagram of a method for arranging steel plates that form a matrix. [Figure 5] These are examples of the arrangement of wear-resistant reinforcements. Figure 5(a) shows an example of a staggered arrangement, and Figure 5(b) shows another example of a staggered arrangement. Figure 5(c) shows an example of the wear-resistant reinforcements arranged diagonally in parallel. [Figure 6] This is an example of the arrangement of wear-resistant reinforcements with rectangular and square bases. [Figure 7] FIG. 7 is a conceptual diagram of the liner shown in FIG. 3, in which the portion of the matrix on the liner surface side is a cast molded plate material. DETAILED DESCRIPTION OF THE INVENTION

[0024] The present invention will be described based on one embodiment of the present invention with reference to the drawings. The present invention is not limited to this embodiment. In the following description, one embodiment of the present invention will be simply referred to as the present invention for convenience.

[0025] [Wear-resistant liner] 1 is a diagram showing an outline of one embodiment of the wear-resistant liner according to the present invention. The wear-resistant liner 1 according to this embodiment is a wear-resistant liner in which a plurality of wear-resistant reinforcements are disposed in a matrix made of one or more alloys in a liner case 4, and the portion of the matrix surrounding the wear-resistant reinforcements that forms the surface side of the wear-resistant liner is made of a cast plate material.

[0026] The wear-resistant liner 1 is typically plate-shaped, with one surface serving as the liner surface (the upper surface in Figure 1), which is the surface against which powders such as raw steel materials and ores collide and slide. The direction perpendicular to the surface is the thickness direction. Therefore, the surface of the wear-resistant liner is typically given wear resistance to extend the life of the liner. In the example of Figure 1, the reinforcing members 3 are rectangular parallelepipeds, arranged in three columns and six rows, for a total of 18 members. However, the shape, arrangement, and number of reinforcing members are not limited to this and can be determined depending on the location where the wear-resistant liner is to be installed.

[0027] Figure 2 shows the wear-resistant liner of Figure 1 as seen from vertically above the surface (Figure 2(a)), and a cross-sectional view (Figure 2(b)) of the AA section (a section perpendicular to the liner surface) of Figure 2(a). Note that the liner case is not shown in Figure 2. Since the capsule used in HIP treatment is often used as the liner case, in the present invention, the portion excluding the liner case may also be referred to as the wear-resistant liner. The reinforcements are surrounded by a matrix alloy to prevent them from coming into contact with each other, which could cause them to break.

[0028] [The matrix on the surface of the liner is made of cast plate material] In the present invention, the alloy that forms the matrix on the surface side of the wear-resistant liner is a cast-formed plate. A cast-formed plate is an alloy plate formed by casting a molten alloy, solidifying it, and then forming it (either hot or cold) into a plate shape. A cast-formed plate formed by melting an alloy, casting it, and then forming it into a plate shape does not have any voids that would occur when the alloy powder is filled, so thermal shrinkage after HIP treatment can be minimized. Furthermore, as will be explained in the manufacturing method described below, this improves the positioning of the reinforcing material inside the capsule during HIP treatment, and also contributes to uniform thermal shrinkage. These effects reduce the in-plane stress on the liner surface that accompanies shrinkage, thereby suppressing cracking.

[0029] There are no particular limitations on the method of forming the cast-formed plate material. It can be hot or cold rolled material, or forged material. For example, steel plate. The size and dimensions of the plate material can be formed to match the shape of the reinforcing material. Since rectangular columns are usually used as reinforcing materials, plate-shaped materials can be fitted to each surface of the rectangular column.

[0030] The matrix obtained by HIPing a cast alloy plate has a different morphology than the matrix obtained by HIPing a powder. The matrix obtained by HIPing a metal powder is formed by solid-state bonding of powders by sintering, and since there are many voids, it has a lower density than a cast alloy plate of the same composition. In other words, when comparing matrices made of alloys of the same composition, the density of the matrix obtained by HIPing a metal powder < the density of the matrix obtained by HIPing a cast alloy plate ≤ the true density of the alloy, so it is possible to distinguish whether the cast alloy plate was HIPed or the metal powder was HIPed.

[0031] By using an alloy as the matrix, the difference in thermal contraction rate between the reinforcement and the alloy after HIP processing allows for the effect of shrink fitting the reinforcement, which means there is no need to take measures to prevent the reinforcement from slipping out (such as creating a recess on the side of the reinforcement), and the shape of the reinforcement can be a simple rectangular column.

[0032] [Reinforced material area ratio on the liner surface: 65% or more] As shown in Figure 2(a), the surface of the wear-resistant liner, excluding the liner case, is composed of an alloy matrix 2 and a reinforcement 3. Increasing the area fraction of the reinforcement can improve the wear resistance of the liner. However, increasing the area fraction of the reinforcement reduces the area fraction of the matrix, narrowing the matrix width between adjacent reinforcements. Conventionally, when alloy powder is HIP-processed to form a matrix, the short distance between adjacent reinforcements can lead to contact between the reinforcements during HIP processing, potentially resulting in breakage. However, in the present invention, a cast plate is sandwiched between adjacent reinforcements during HIP processing, preventing contact between the reinforcements during HIP processing. This allows for a narrower matrix width between the reinforcements. In other words, the area fraction of the reinforcement on the wear-resistant liner surface can be significantly increased. Even with the same reinforcement and matrix width, the larger the liner surface area, the higher the area fraction of the reinforcement. Therefore, there is no particular upper limit to the area fraction of the reinforcement on the wear-resistant liner surface. In practice, a reinforcement area fraction of 95% or less is preferred.

[0033] There is no particular lower limit for the area ratio of the reinforcement on the liner surface. This can be achieved by simply increasing the matrix width. However, while increasing the matrix width does indeed suppress matrix cracking compared to conventional liners with a powder matrix, the wear resistance remains the same. Therefore, the area ratio of the reinforcement is preferably 65% ​​or more, and more preferably 70% or more, 75% or more, or 80% or more.

[0034] [Matrix Width] The wear-resistant liner of the present invention can narrow the matrix width (the distance between adjacent reinforcements) because, unlike powder compression, the use of a cast-molded plate material prevents shrinkage of voids that exist during powder packing, and because it is a continuous body, adjacent reinforcements do not come into contact with each other during HIP processing.

[0035] Considering the need to prevent the reinforcement from coming loose, the matrix width in the liner should realistically be 3.0 mm or greater. A matrix width of 3.0 mm prevents the reinforcement from coming into contact with each other during HIP processing due to damage to the cast plate material that serves as the matrix. Preferably, the matrix width is 3.5 mm or greater, 4.0 mm or greater, 4.5 mm or greater, or 5.0 mm or greater. The upper limit of the matrix width is not particularly limited and can be determined appropriately based on the size of the liner and the size of the reinforcement. However, if the matrix width is too large, the advantages over conventional liners with a powder matrix are lost. Therefore, the matrix width is preferably 10.0 mm or less, 9.0 mm or less, 8.0 mm or less, or 7.0 mm or less. A thinner matrix width allows for a higher reinforcement area ratio on the liner surface, ensuring wear resistance. In this case, the matrix width is preferably set so that the reinforcement area ratio on the liner surface is 65% to 95%. Furthermore, in conventional HIP treatment using metal powder, the thinner the matrix width, the greater the risk of the reinforcement coming into contact and being damaged during the HIP treatment. However, in the present invention, this risk is significantly reduced, allowing the user to enjoy the benefits of the present invention to a great extent.

[0036] [alloy] The alloy components for the matrix (including cast plate materials) are not particularly limited. They can be selected from the powders, ores, etc., that are subject to wear by the liner, and an alloy with wear resistance to these materials is recommended. Examples of wear-resistant alloys include high-Cr cast iron containing 12 to 30 wt% Cr and 1 to 3 wt% C with added Si, Mn, Ni, Cu, Mo, W, etc., and high-speed steel (high-speed tool steel, various alloys specified by JIS SKH). Since the wear-resistant liner of the present invention can reduce the surface area of ​​the matrix and allow the wear resistance to be borne by the reinforcing material, stainless steel or general steel (especially mild steel) can also be used for the matrix alloy. Stainless steel can also provide corrosion resistance, while mild steel can reduce the manufacturing cost of the wear-resistant liner. One of these steel types may be selected, or two or more types may be combined depending on the location within the liner. For example, high-speed steel or wear-resistant cast iron can be used for the matrix that flows in the same direction as the flow direction of the powders or ores that are subject to wear, and mild steel or stainless steel can be used for the matrix that flows perpendicular to the flow direction.

[0037] [Wear-resistant reinforcement material] Ceramics, cemented carbide, etc. can be used as the reinforcing material. The type of ceramic is not particularly limited, and may be, for example, Si3N4, sialon, SiC, ZrO2, Al2O3, etc. The cemented carbide is also not particularly limited, and may be, for example, not only WC-Co, but also a composite carbide obtained by adding TiC, TaC, etc. to WC, or one in which Co is replaced with Ni, Ni-Cr, Ni-Mo, etc. In other words, at least one of ceramics and cemented carbide is sufficient, and both may be used.

[0038] The shape of the wear-resistant reinforcement is not particularly limited. However, since a cast plate formed into a plate shape is used as the matrix, it is preferable that the reinforcement be a polygonal prism with flat sides. In particular, a shape of the reinforcement that ensures a constant matrix width between adjacent reinforcements is preferable. For example, it is preferable that the reinforcement be a cube or rectangular prism. For example, the reinforcement shown in Figures 1 to 3 is an example of a rectangular prism. It may also be a triangular prism with a right-angled triangular or equilateral triangular base, or a regular hexagonal prism. These shapes allow reinforcements of the same shape to be arranged. Of course, reinforcements with irregularly shaped rectangular prism bases may be combined.

[0039] [Liner case] There are no particular restrictions on the shape or material of the liner case. In many cases, the liner case serves both to attach the wear-resistant liner to the target equipment and as a capsule during HIP treatment, so it is best to select the shape and material taking these functions into consideration.

[0040] When the liner case also serves as a capsule for HIP treatment, mild steel is usually used. This is because it is easy to process and easily deforms during HIP treatment, making it easy to transmit pressure to the interior (i.e., the cast plate material that serves as the reinforcement and matrix). Furthermore, in order to attach it to the target equipment, it must be molded into a shape that corresponds to the installation location. From this perspective, if the liner case is made of mild steel, it will have better formability after HIP treatment. Of course, the liner case itself may have wear resistance, but in the present invention, the surface area ratio of the reinforcement can be increased, so the liner case does not need to be burdened with wear resistance, allowing for greater freedom in material selection and shape design.

[0041] [Improved wear resistance of the matrix on the liner surface] It is effective to use an alloy with excellent wear resistance for the portion of the matrix that will be on the surface side of the wear-resistant liner. If the matrix has poorer wear resistance than the wear-resistant reinforcement, the matrix will wear preferentially, determining the life of the wear-resistant liner. Therefore, improving the wear resistance of the matrix will lead to a longer life of the liner. Therefore, it is desirable to strengthen the wear resistance of at least the portion of the matrix that will be on the surface side of the liner.

[0042] FIG. 7 is a schematic diagram illustrating an example in which the portion 24 of the matrix on the liner surface side of the liner shown in FIG. 3 is formed from a cast plate. As shown in FIG. 7, the portion of the matrix that will become the wear-resistant liner surface is not particularly limited in its length in the liner depth direction, as long as it faces the liner surface. The length of the cast plate in the liner depth direction is preferably at least as long as the matrix width (the width of the adjacent reinforcement) is equal to or greater than 3 mm, 4 mm, 5 mm, 7 mm, or 10 mm. Of course, it may be the same length as the reinforcement length. However, since highly wear-resistant alloys are generally expensive, it is desirable from an economical standpoint to use a highly wear-resistant alloy only for the necessary length (the portions that would wear if the other portions 21 and 23 were made of an alloy).

[0043] Examples of highly wear-resistant alloys include high-Cr alloys, high-speed steels, and wear-resistant steels (such as ABREX manufactured by Nippon Steel Corporation). One or more of these alloys may be used depending on the location of the liner.

[0044] When the depth of the reinforced wear resistance portion does not extend over the entire length of the reinforcement in the depth direction of the liner, particularly when it is less than 50% of the length of the reinforcement, a powder of highly wear-resistant alloy may be HIP-treated and used in a portion of the liner other than the surface portion in the thickness direction (depth direction). However, it is preferable to use a cast plate of a highly wear-resistant alloy for the entire surface portion in the thickness direction of the liner. By using a cast plate, thermal shrinkage after HIP treatment can be minimized, and cracking can be suppressed.

[0045] The alloy for the portions 21 and 23 other than the portion 24 on the liner surface side of the matrix is ​​as explained above. Since the portions of the liner surface that require wear resistance have enhanced wear resistance, mild steel or stainless steel may be used for the portions of the matrix other than the portion 24 on the liner surface side. In fact, using a versatile material such as mild steel improves workability and corrosion resistance, and improves the ease of installation in various types of equipment.

[0046] [Manufacturing method] An embodiment of the method for manufacturing the wear-resistant liner of the present invention will be described. There are no limitations on the manufacturing method as long as it satisfies the requirements for the wear-resistant liner and the requirements for the wear-resistant liner structure defined in the present invention. However, from the viewpoint of firmly bonding the different materials of the reinforcing material and the matrix, it is preferable to manufacture the wear-resistant liner by hot pressing or HIP (hot isostatic pressing). Furthermore, manufacturing the wear-resistant liner by hot pressing or HIP clearly contrasts with conventional methods using alloy powder as the matrix, and significant advantages can be obtained. Hereinafter, the manufacturing of the wear-resistant liner shown in Figures 1 and 2 by HIP will be described as an example.

[0047] <Preparation steps> In the preparation step, at least a liner case, a wear-resistant reinforcement, and a cast plate formed by casting an alloy and then shaping it into a plate are prepared. For example, a rectangular ceramic wear-resistant reinforcement is prepared, a high-speed steel plate is prepared as the cast plate for the alloy that will serve as the matrix, and a mild steel liner case that will also serve as a capsule for the HIP treatment is prepared. In addition, an alloy that will serve as the matrix other than the cast plate that will serve as the matrix on the liner surface, such as a base alloy plate (stainless steel plate, mild steel plate, etc.), or an alloy plate or powder alloy that will be combined with the cast plate in the plate thickness direction, is prepared.

[0048] <Encapsulating Step> Next, in the encapsulation step, the reinforcement material and cast plate prepared in the preparation step are placed in a liner case, which also serves as a capsule for the HIP treatment. Here, the cast plate material that will serve as the matrix on the surface of the liner is placed so that it is in contact with the liner surface. Figure 3 shows an example of the arrangement of the reinforcement material and the steel plate that will serve as the matrix before the HIP treatment. Figure 3 shows a vertical top view of the wear-resistant liner (Figure 3(a)) and a cross-sectional view (Figure 3(b)) of the AA section of Figure 3(a) (a section perpendicular to the surface of the wear-resistant liner). Note that Figure 3 also shows an example in which the cast plate material is a steel plate. That is, the reinforcement material 3 and the steel plate that will serve as the matrix (vertical steel plate 21 and horizontal steel plate 22) are placed in a liner case (not shown). As shown in Figure 3, the reinforcement material 3 and the steel plate that will serve as the matrix (21 and 22) can be placed in the same manner as the final wear-resistant liner structure. Both the steel plate that will serve as the matrix (21 and 22) and the reinforcement material 3 can be placed closely due to their high processing precision. If a small gap occurs between the steel plates 21, 22 and the reinforcing material 3, it is acceptable to fill the gap with alloy powder. This is because filling the gap with alloy powder can fill the gap and reduce the shrinkage rate during HIP treatment. It is desirable that the alloy powder to be filled is of the same type as the alloy that will become the matrix.

[0049] FIG. 4 is also an explanatory diagram of an example of a method for arranging reinforcement 3 and matrix steel plates 21 and 22 within a liner case (not shown). First, the reinforcement 3 is arranged on a base steel plate 23. The base steel plate 23 also becomes the matrix after HIP processing. Instead of the base steel plate 23, the reinforcement may be placed directly on the liner case (not shown). The matrix steel plates 21 and 22 are then arranged between adjacent reinforcements 3 (or between the liner case and the reinforcement in the case of edge reinforcements). For example, steel plates 22 are arranged horizontally to cover the entire horizontal length of the liner surface, and steel plates 21 corresponding to the vertical length of the reinforcement are arranged vertically on the liner surface to fill the gaps between the horizontal steel plates. While FIG. 4 shows up to six reinforcements arranged, this is for ease of explanation and the number of reinforcements to be arranged is not particularly limited. After all the required number of reinforcements are arranged, horizontal steel plates 22 and vertical steel plates 21 may be arranged between them, respectively. Alternatively, one reinforcing material 3 may be placed, followed by the horizontal steel plate 22 and the vertical steel plate 21. In this way, the reinforcing material 3 and the steel plate 2 that will become the matrix (the horizontal steel plate 22 and the vertical steel plate 21) can be placed in a liner case (not shown), as shown in Figures 3(a) and 3(b).

[0050] Figures 3 and 4 show examples of parallel arrangement of reinforcement materials in rectangular parallelepipeds with square bases. However, the reinforcement materials can also be arranged in a staggered pattern, as shown in Figure 5(a). A staggered arrangement prevents the matrix from being continuously connected, thereby suppressing selective matrix wear. In particular, preventing the matrix from being continuous in the direction of wear (the direction of flow of powder or ore sliding on the liner surface) can suppress selective matrix wear. Figure 5(b) shows another example of a staggered arrangement. Figure 5(c) shows an example of a reinforcement material arranged diagonally to the direction of wear. Figure 6 shows an example of a combination of reinforcement materials consisting of rectangular parallelepipeds and square parallelepipeds, where the matrix is ​​not continuous in either the vertical or horizontal direction. This arrangement, like the staggered arrangement, can suppress selective matrix wear.

[0051] Once the required reinforcement materials and the cast molding plate material that will become the matrix have been placed inside the liner case, the liner case is sealed with a lid in preparation for HIP treatment. At this time, the pressure inside the liner case is reduced. This reduces the pressure, creating a vacuum inside the capsule. The pressure reduction method and set pressure can be the same as for normal HIP treatment.

[0052] When the wear resistance of the matrix in the surface portion of the wear-resistant liner is to be enhanced, a highly wear-resistant alloy may be disposed in the portion of the matrix that will be on the surface side of the wear-resistant liner (the portion where the wear resistance of the matrix is ​​to be enhanced) during the encapsulating step. As described above, if the depth of the portion where wear resistance is to be enhanced does not extend over the entire length of the reinforcement in the thickness direction of the liner, particularly if it is less than 50% of the length of the reinforcement, alloy powder of a highly wear-resistant alloy may be used and disposed in part of the matrix in the thickness direction of the liner other than the portion on the surface side. Regardless of the depth of the portion where wear resistance is to be enhanced, a cast plate of a highly wear-resistant alloy may be disposed on the entire surface portion of the matrix in the in-plane direction of the liner. As described above, the highly wear-resistant alloy may be one or more of a high-Cr alloy, high-speed steel, and wear-resistant steel.

[0053] <HIPステップ> In the HIP step, the capsules prepared in the encapsulating step are loaded into a HIP device and subjected to HIP treatment. The HIP treatment conditions may be appropriately selected according to known HIP methods. For example, heating (e.g., 900°C to 1400°C) and pressurization (e.g., 90 MPa to 200 MPa) may be performed. After the HIP treatment is completed, the capsules are removed from the HIP device and molded to obtain a wear-resistant liner with the desired shape. Note that when the capsules are heated and pressurized to manufacture the liner, the liner shrinks. This is a natural and predictable occurrence in the HIP method. Therefore, the capsule size can be determined taking into account the shrinkage. This can also be set by applying known HIP methods. However, by applying the present invention, this shrinkage is smaller than that in conventional HIP treatments using metal powder, and this must be taken into consideration. By using HIP, even if the cast plate has one or more high-Cr alloys, high-speed steels, and wear-resistant steels on the surface side of the wear-resistant liner of the matrix and stainless steel or mild steel in the remaining portions, the cast plates can be diffusion-bonded together at the contact points, resulting in a strong integration. Furthermore, by using HIP, the reinforcing material and the cast plate placed around the reinforcing material (sides and bottom) are deformed in a direction that brings the reinforcing material and the cast plate into close contact during heating and pressurization. During the subsequent cooling, the difference in thermal contraction rates between the reinforcing material and the cast plate causes compressive stress of the cast plate to act on the reinforcing material, resulting in a shrink-fit integration between the two.

[0054] Steel plates shrink less during HIP treatment than alloy powders, so by surrounding the reinforcing material with steel plates and then performing HIP treatment, it is possible to prevent the reinforcing material from shifting or tilting compared to metal powders. Furthermore, when a base steel plate is used as the matrix, the base steel plate may have openings or recesses in advance at the locations where the reinforcing materials will be placed. By using a base steel plate with openings or recesses, it becomes easier to position the reinforcing materials, and it is also possible to prevent the reinforcing materials from shifting or tilting during the HIP treatment.

[0055] <Processing steps> The capsule (liner case) that has undergone HIP processing is processed into a predetermined shape. For example, the liner case may be machined after HIP processing to create a shape that fits the equipment on which the wear-resistant liner will be mounted. A mounting jig for the equipment may also be attached. The processing method is not particularly limited; ordinary machining, welding, or other processing methods may be used.

[0056] The liner case on the surface side of the wear-resistant liner does not necessarily need to be removed. This is because the surface side is exposed to an abrasive environment due to the sliding of powders, ores, etc., and will be worn away. When the liner case on the surface side is worn away, the wear-resistant reinforcement material will appear on the surface, providing wear resistance. [Example]

[0057] As the wear-resistant liner according to the present invention, a liner case (also used as a HIP capsule), a reinforcing material, and various cast alloy plates were prepared as the matrix alloy. Also prepared were cast alloy plates and insert reinforcements that would become the wear-reinforced portion on the surface side of the matrix liner. The specifications of these were as follows:

[0058] <Abrasion-resistant liner> Wear-resistant liner dimensions (inner dimensions of case before HIP treatment): W415~586mm×D162~234mm×H45mm Arrangement of reinforcements in the wear-resistant liner: (horizontal) 18 pieces x (vertical) 7 pieces = 126 pieces arranged Material: Mild steel

[0059] <Reinforcement material> Dimensions: W22mm x D22mm x H37mm Material: Si3N4 (ceramics)

[0060] <Cast molding plate material> Plate width: 0.5mm, 5mm, 10mm (same as matrix width after HIP) Material: High chrome steel, mild steel Shape: Plate (steel plate)

[0061] <Alloy powder for comparative materials> Matrix width: 1mm, 10mm Particle size (average): 0.1 μm (gas atomized product) Material: High-speed steel, mild steel Shape: powder

[0062] The reinforcement material and cast-formed plate were placed in the prepared liner case, and in some test pieces, cast-formed plate material for the wear-resistant reinforcement on the surface of the liner and insert material were placed, and then lids were placed to create five capsules for HIP treatment. Five wear-resistant liners for testing were then produced using the HIP method. After HIP treatment, the liner case corresponding to the surface was removed by machining, and a visual inspection was performed, and the presence or absence of cracks in the matrix alloy was confirmed using fluorescent flaw detection. The results are shown in Table 1.

[0063] [Table 1]

[0064] Next, they were installed in an actual steelmaking blast furnace and a comparative wear resistance test was conducted. Two pieces each of test materials 1-1, 1-3, 2-1, and 2-3 were installed on the inner surface of the rotating chute, which is equipment used to charge steel raw materials into the blast furnace, as wear-resistant liners for the rotating chute. Two pieces each of comparative examples 3-3 and 4-3 were also installed on the inner surface of the rotating chute as comparison examples. The actual equipment was operated and the wear conditions were confirmed. Comparative examples 3-1 and 4-1 could not be used in wear resistance tests on the actual equipment because some of the reinforcing material was damaged by contact during HIP treatment.

[0065] After approximately six months of continuous operation, the liners were removed and visually inspected for wear. The results showed that the liner of Test Material 1-1 had no cracks in the reinforcement and minimal matrix wear, demonstrating good wear resistance. Test Material 1-3 showed wear to a depth of 2 to 5 mm in some of the matrix. Test Material 2-1 showed wear to a depth of 5 to 10 mm in the matrix. Test Material 2-3 showed overall wear to a depth of 10 to 15 mm, and the edges (corners) of the reinforcement were slightly worn, but this did not affect the liner's wear resistance. The liners of Comparative Materials 3-3 and 4-3 showed more severe matrix wear than Test Materials 1-3 and 2-3, which used the same matrix material. Some edges (corners) of the reinforcement were worn away, and one or two cracks were observed.

[0066] However, upon closer observation, it was found that the selective wear of the matrix differed among the test materials, with the amount of matrix wear increasing in the order of test materials 1-1, 1-3, 2-1, and 2-3. Furthermore, when comparing test materials 1-3 and 2-3 with comparative materials 3-3 and 4-3, the amount of matrix wear was similar overall, but the comparative materials had selective wear in the areas where the reinforcement spacing was wider. This is thought to be because the reinforcement in the comparative materials moved or tilted during HIP processing, resulting in an uneven matrix width. Test materials 1-1, 1-3, 2-1, and 2-3 had uniform reinforcement placement, and no localized selective wear occurred within the matrix.

[0067] Test materials 1-1 and 2-1, which have narrower matrix widths, are thought to have been superior in terms of wear resistance due to their improved wear resistance. On the other hand, when the matrix width is wider, the matrix formed by HIPing the alloy powder also has a dense structure, so the liner structure of the test materials and the comparative materials is thought to be equivalent, but the comparative material using alloy powder had fine cracks generated in the matrix due to HIP, which is thought to have resulted in more wear of the matrix.

[0068] From the above, it was confirmed that strengthening the wear resistance of the matrix on the surface side of the liner is effective from the viewpoint of improving the wear resistance of the entire liner. [Industrial Applicability]

[0069] The present invention can be used in any industry that uses powders, ores, etc. [Explanation of symbols]

[0070] 1. Abrasion resistant liner 2. Matrix 2a, 2b, 2c, 2d matrix alloy layers 3. Wear-resistant reinforcement 4 Liner Case 21 Matrix steel plate (longitudinal direction) 22 Matrix steel plate (horizontal direction) 23 Matrix steel plate (base) 24 Matrix on the surface of the liner (cast molding plate material)

Claims

1. A wear liner comprising a plurality of wear-resistant reinforcements disposed in a matrix of one or more alloys, 1. A wear-resistant liner, wherein at least a surface side of the wear-resistant liner in the matrix surrounding the wear-resistant reinforcement is made of a cast plate material.

2. 2. The wear-resistant liner according to claim 1, wherein the cast plate material on the surface side of the wear-resistant liner in the matrix is ​​one or more of a high Cr alloy, a high-speed steel, and a wear-resistant steel.

3. 3. The wear-resistant liner according to claim 2, wherein the matrix is ​​made of stainless steel or mild steel except for the portion that is to become the surface side of the wear-resistant liner.

4. 4. The abrasion liner according to claim 1, wherein the area ratio of the abrasion resistant reinforcement material on the surface of the abrasion liner is 65% or more.

5. 4. The abrasion liner according to claim 1, wherein the matrix has a width of 3.0 mm or more.

6. The wear-resistant reinforcement is Si ３ N ４ , SiC, and Al ２ O ３ The abrasion resistant liner according to any one of claims 1 to 3, which is one or more of the following:

7. 4. The wear-resistant liner according to claim 1, wherein the wear-resistant reinforcement is a polygonal column.

8. 8. The wear liner according to claim 7, wherein the polygonal prism is a cube or a rectangular parallelepiped.

9. A method for manufacturing the abrasion-resistant liner according to any one of claims 1 to 3, a preparation step of preparing a cast plate material by casting at least a liner case, one or more types of wear-resistant reinforcement material, and one or more types of alloy and then forming the cast plate material into a plate shape; an encapsulating step including disposing a plurality of the wear-resistant reinforcements and the cast plate material that forms a matrix around the wear-resistant reinforcements inside the liner case so as to contact the surface of the liner; A method for manufacturing a wear-resistant liner, comprising a HIP step of HIP-treating the liner case in which the plurality of wear-resistant reinforcements and the cast plate material are arranged.

10. 10. The method for manufacturing a wear-resistant liner according to claim 9, wherein the encapsulating step includes disposing a cast plate material on the surface side of the wear-resistant liner in the matrix, the cast plate material being made of one or more of a high Cr alloy, a high-speed steel, and a wear-resistant steel.

11. The method for manufacturing a wear-resistant liner according to claim 9 or 10, further comprising a processing step of machining the liner case after the HIP treatment step.

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