Composite Hard-Surface Material via Overlay Welding
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Solution Overview
Problem
Existing hard-face materials fail to provide adequate abrasion and corrosion resistance for components operating in harsh conditions, such as high erosional, acidic, or alkaline environments, due to decreased hardness from sintering and weak bonding from spray welding, leading to deformation and peeling issues.
Innovation Solution
A composite hard-face material is prepared by dispersively fixing hard-alloy sheets on a metal matrix using a solder comprising nickel-based alloy powder, tungsten carbide particles, and boron nitride powder, followed by overlay welding, which enhances abrasion resistance through improved bonding and hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sintering is used to prepare composite hard-face material, then the material has good corrosion resistance, but the matrix hardness decreases due to high sintering temperature causing deformation
Solution Approach 1:
The invention divides the hard-face material into discrete hard-alloy sheet segments dispersed on the matrix surface, rather than using a fully sintered composite structure. This segmentation allows the matrix to maintain its hardness while the dispersed sheets provide the necessary corrosion and wear resistance.
Solution Approach 2:
The invention changes the preparation parameters by using overlay welding instead of high-temperature sintering. This parameter change allows the matrix to retain its original hardness properties while still achieving a composite structure with improved corrosion resistance through the solder containing nickel-based alloy powder and tungsten carbide particles.
2Reliability
If spray welding is used to prepare composite hard-face material, then the material has good abrasion resistance, but the bonding between hard face layer and matrix is weak causing peeling
Solution Approach 1:
The invention uses a composite solder structure containing nickel-based alloy powder, tungsten carbide particles, and boron nitride powder. This composite material provides both strong metallurgical bonding to the matrix and enhanced abrasion resistance, eliminating the weakness of conventional spray welding where the bonding strength is insufficient.
Solution Approach 2:
The overlay-welded solder acts as an intermediary layer between the hard-alloy sheets and the metal matrix. This intermediate layer provides strong bonding to both substrates while containing hard particles that enhance abrasion resistance, solving the dual requirement of strong bonding and wear resistance.
3Strength
If spray welding is used to prepare composite hard-face material, then the material has moderate bonding strength, but microporosity of 2% to 5% reduces abrasion resistance
Solution Approach 1:
The invention replaces the spray welding process with overlay welding, which uses a different mechanical and thermal mechanism. The overlay welding process creates a denser structure with significantly reduced microporosity by using controlled deposition and metallurgical bonding, eliminating the porosity issue inherent in spray welding while maintaining strong bonding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a composite hard-face material with excellent abrasion resistance, as demonstrated by reduced wear and improved durability in testing, effectively addressing the limitations of previous technologies.
Implementation Method 1
overlay welding the hard-alloy sheets and the metal matrix using a solder
Implementation Method 2
the solder comprises nickel-based alloy powder, tungsten carbide particles, and boron nitride powder
Implementation Method 3
the solder comprises nickel-based alloy powder, tungsten carbide particles, and boron nitride powder
Implementation Method 4
the solder comprises nickel-based alloy powder, tungsten carbide particles, and boron nitride powder
Implementation Method 5
dispersedly fixing the plurality of hard-alloy sheets on the surface of a metal matrix by spot welding
Data Source
AI summary
A composite hard-surface material preparation method and a composite hard-surface material prepared thereby, the preparation method comprising: dispersedly fixing a plurality of cemented carbide sheets (2) to a surface of a metal substrate (1); and surfacing the cemented carbide sheets (2) and the metal substrate (1) with a solder (3) to obtain a composite hard-surface material, the solder (3) comprising nickel-based alloy powder, tungsten carbide particles and boron nitride powder. The solder (3) used in the preparation of the composite hard-surface material comprises nickel-based alloy powder, tungsten carbide particles and boron nitride powder, wherein the nickel-based alloy powder can increase fluidity and corrosion resistance, the tungsten carbide particle can improve hardness, and the boron nitride powder can effectively reduce friction coefficient. The present solder has good fluidity, high hardness and good solderability, using said solder, the obtained composite hard-surface material may enjoy good wear resistance.