CN110241352B - Abrasion-resistant composite material for water turbine and preparation method and application thereof - Google Patents
Abrasion-resistant composite material for water turbine and preparation method and application thereof Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/03—Making non-ferrous alloys by melting using master alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/04—Making ferrous alloys by melting
- C22C33/06—Making ferrous alloys by melting using master alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/42—Ferrous alloys, e.g. steel alloys containing chromium with nickel with copper
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
Abstract
The application discloses an abrasion-resistant composite material for a water turbine and a preparation method and application thereof, wherein the material is compounded by iron-based amorphous and boride synthesized in situ; the composite material comprises the following components in percentage by weight: 26wt% of Cr, 5-15wt% of B, 3wt% of Si, 3wt% of Cu, 5wt% of Ni, 10wt% of Mo and the balance of Fe. The raw materials for preparing the composite material are added into a vacuum gas atomization furnace for smelting, atomizing and screening the powder, so that the amorphous/boride composite powder can be obtained. The application of the powder in preparing the abrasion-resistant composite coating adopts a supersonic flame spraying technology to prepare the coating. The invention can obtain the composite coating with good bonding strength with the matrix, high hardness and excellent abrasion resistance, and has wide application prospect.
Description
Technical Field
The invention belongs to the field of thermal spraying of material processing engineering, and particularly relates to an abrasion-resistant composite material for a water turbine, and a preparation method and application thereof.
Background
The water turbine is a power machine which converts the energy of water flow into rotary mechanical energy and is one of the main devices of the hydropower station. In the running process of the water turbine, the water turbine blades, the rotating wheel body, the guide vanes and other flow passage components are often abraded by water and sand to cause surface metal loss, so that equipment generates vibration and noise in running, the running efficiency of the equipment is low, the overhaul is frequent, and the service life is shortened. By erosion is meant the phenomenon of material destruction under the combined action of cavitation erosion and silt abrasion, which is unavoidable during operation of the turbine. Therefore, improving the abrasion resistance of the water turbine becomes one of the research hotspots in the hydroelectric power generation industry.
Since erosion of materials often occurs at the surface, the use of suitable surface protection techniques to produce an erosion resistant coating is an effective means of improving erosion performance of water turbines. Supersonic flame (HVOF) spraying has the characteristics of high flame flow speed and relatively low flame flow temperature, so that the prepared coating has good bonding strength and hardness, and the thickness of the coating is controllable, and the coating is considered to be an advanced surface protective coating preparation technology and is widely applied to various fields of industrial production. In recent years, protective coatings prepared by HVOF spraying technology are beginning to be applied to the aspect of abrasion resistance and protection of water turbines, such as water turbine blades of units of a three gorges hydropower station, a Liu's gorges hydropower station and the like. The existing HVOF spraying water turbine protective coating is generally a WC-based metal ceramic coating, but the WC-based metal ceramic coating has low fracture toughness and an interface between WC and a bonding phase exists, so that an abrasion crack is easy to generate and expand along the interface between WC and the bonding phase, and the abrasion resistance problem of the water turbine cannot be thoroughly solved.
As a novel structure and function material, the amorphous alloy has the defects of no crystal boundary, dislocation and the like, has high hardness, good wear resistance and corrosion resistance, and has been widely applied in the industries of electronics, machinery, chemical engineering and the like, wherein the iron-based amorphous material is one of the research hotspots of the amorphous alloy in recent years due to low preparation cost. The HVOF technology is used for preparing the iron-based amorphous coating, and a novel protective coating with good abrasion resistance is hopeful to be obtained. Numerous studies have shown that the addition of a second phase hard compound to a material can further improve the abrasion resistance of the material. However, the bonding interface between the foreign second phase and the matrix material tends to be a weak point of composite failure. If the boride is synthesized in situ in the amorphous matrix through component design, on one hand, the advantages of stable chemical property and high hardness of the boride can be exerted, and on the other hand, a clean amorphous/boride interface can be obtained, so that the interface cracking is effectively delayed, and the overall performance of the composite material is improved.
In conclusion, the iron-based alloy powder with high amorphous forming capability is designed, sufficient boron is added to obtain the amorphous/boride composite material for in-situ synthesis of boride, and the composite protective coating with high abrasion resistance is prepared on the surface of the water turbine, so that the iron-based alloy powder has important practical significance.
Disclosure of Invention
The technical problem to be solved is as follows: the application mainly provides an abrasion-resistant composite material for a water turbine and a preparation method and application thereof, and solves the technical problems of low equipment operation efficiency, frequent overhaul, short service life and the like in the prior art.
The technical scheme is as follows:
the abrasion-resistant composite material for the water turbine is characterized by comprising the following chemical components in percentage by weight: 26wt% of Cr, 5-15wt% of B, 3wt% of Si, 3wt% of Cu, 5wt% of Ni, 10wt% of Mo and the balance of Fe.
The invention also provides a preparation method of the abrasion-resistant composite material for the water turbine, which comprises the following steps:
the first step is as follows: proportioning according to the weight percentage of chemical components, weighing materials of low-carbon ferrochrome, high-carbon ferrochrome, ferroboron, ferrosilicon, electrolytic copper, electrolytic nickel, ferromolybdenum and pure iron, sequentially adding the materials into a vacuum induction electromagnetic oven according to the sequence of high-to-low melting points and the principle of adding the materials containing elements easy to burn and damage, then heating to 2000 ℃, and preserving heat for 10 min;
the second step is that: vacuum atomizing the molten liquid at 3MPa, drying at 80 deg.C, and sieving to obtain powder with particle size of 15-45 μm.
As a preferred technical scheme of the invention: in the first step, the temperature in the vacuum induction electromagnetic oven is increased to 2000 ℃ at the speed of 10K/s, and the heat preservation time is 10 min; in the second step, the drying temperature of the powder is 80 ℃, and the drying time is 2 hours.
In addition, the invention also provides application of the abrasion-resistant composite material for the water turbine in preparation of an abrasion-resistant iron-based amorphous/boride coating.
As a preferred technical scheme of the invention: the application of the abrasion-resistant composite material for the water turbine in preparing the abrasion-resistant iron-based amorphous/boride coating comprises the following steps:
the first step is as follows: pretreating the surface of the substrate: after removing rust and oil on the surface of the matrix, performing sand blasting and coarsening on the surface of the matrix by adopting brown corundum sand with the granularity of 5-35 meshes under the air pressure of 0.7-0.8 MPa;
the second step is that: spraying on the surface of the substrate by adopting a supersonic flame spraying technology, wherein the spraying process parameters are as follows: the oxygen flow is 2000 scfh, the kerosene flow is 6.8 gph, the spraying distance is 330 mm, the carrier gas flow is 23 scfh, the rotating speed of the powder feeder is 5.5 rpm, and the moving speed of the spray gun is 280 mm/s.
The mechanism of the invention is as follows: the iron-based amorphous/boride composite material consists of seven elements, wherein Mo is a large atom, Cu, Cr, Ni and Fe are intermediate atoms, B, Si is a small atom, the mixing enthalpy among the main atoms is negative, the mismatching degree of the atom size is large, and therefore the amorphous forming capability is high. Amorphous materials have a higher hardness than crystalline materials of the same composition, and therefore the rate of material loss during abrasion is lower. In addition, CrB, FeB and Fe are synthesized in situ in the amorphous phase by increasing the content of B2B and other borides can effectively improve the hardness and the abrasion resistance of the composite material. The boride synthesized in situ can not only play a role in dispersion strengthening, but also obtain a clean amorphous/boride interface with high bonding strength. Therefore, compared with the traditional pure amorphous material or the composite material added with the second phase, the composite material of the invention has higher hardness and higher bonding strength between phase interfaces, the time for starting the formation of the crack during abrasion is delayed, and the crack propagation speed is slowed down after the formation, so the abrasion weight loss rate is smaller, and the abrasion resistance of the material is further improved.
Has the advantages that: compared with the prior art, the abrasion-resistant composite material for the water turbine and the preparation method and application thereof adopt the technical scheme, and have the following technical effects:
1. the protective coating with high hardness and excellent abrasion resistance can be obtained, the industrialization is easy, and the application prospect is wide.
2. By adjusting the types of the added atoms and the proportion of the atoms, the atoms have a large degree of atom mismatching, so that the designed iron-based alloy system has good amorphous forming capability and stability.
3. By further regulating the content of boron, boride is synthesized in situ in the iron-based amorphous matrix, and a coating with high hardness and excellent abrasion resistance is obtained.
4. The prepared iron-based amorphous/boride composite coating for the abrasion resistance of a water turbineThe bonding strength is more than or equal to 100 MPa, and the hardness is more than or equal to 750 HV0.3The abrasion volume loss rate is less than or equal to 0.05 mm3/h。
Detailed Description
The present invention will be better understood from the following examples. However, those skilled in the art will readily appreciate that the specific material ratios, process conditions and results thereof described in the examples are illustrative only and should not be taken as limiting the invention as detailed in the claims.
In the embodiment, the bonding strength of the coating is measured by a stretching method, and FM-1000 glue (the bonding strength is 100 MPa) is selected as a bonding agent; measuring the microhardness of the coating by using an HXD-1000TC microhardness tester, wherein the test load is 300g, and the load retention time is 15 s; the abrasion test was carried out on a rotating disk test stand, in which the flow rate of water was set at 33 m/s and the sand content was set at 20 kg/m3And judging the abrasion resistance of the coating according to the volume loss rate.
Example 1
An abrasion resistant composite material for a hydraulic turbine, a method for preparing the abrasion resistant composite material for the hydraulic turbine, comprising the steps of:
the first step is as follows: weighing low-carbon ferrochrome, high-carbon ferrochrome, ferroboron, ferrosilicon, electrolytic copper, electrolytic nickel, ferromolybdenum and pure iron according to the chemical components of 26wt% of Cr, 5wt% of B, 3wt% of Si, 3wt% of Cu, 5wt% of Ni, 10wt% of Mo and the balance of Fe for proportioning, sequentially adding the materials into a vacuum induction electromagnetic furnace according to the sequence of melting points from high to low and the principle of adding the materials containing elements easy to burn and damage finally, heating to 2000 ℃ at the speed of 10K/s, and preserving heat for 10min to completely melt the materials;
the second step is that: vacuum atomizing the molten liquid at 3MPa, drying at 80 deg.C for 2 hr, and sieving to obtain powder with particle size of 15-45 μm.
The application of the abrasion-resistant composite material for the water turbine in preparing the abrasion-resistant iron-based amorphous/boride coating comprises the following steps:
the first step is as follows: pretreating the surface of the substrate: after removing rust and oil on the surface of the matrix, performing sand blasting and coarsening on the surface of the matrix by adopting brown corundum sand with the granularity of 5-35 meshes under the air pressure of 0.7-0.8 MPa;
the second step is that: spraying on the surface of the substrate by adopting a supersonic flame spraying technology, wherein the spraying process parameters are as follows: the oxygen flow is 2000 scfh, the kerosene flow is 6.8 gph, the spraying distance is 330 mm, the carrier gas flow is 23 scfh, the rotating speed of the powder feeder is 5.5 rpm, and the moving speed of the spray gun is 280 mm/s.
Example 2
An abrasion resistant composite material for a hydraulic turbine, a method for preparing the abrasion resistant composite material for the hydraulic turbine, comprising the steps of:
the first step is as follows: according to the weight percentage of chemical components: 26wt% of Cr, 10wt% of B, 3wt% of Si, 3wt% of Cu, 5wt% of Ni, 10wt% of Mo and the balance of Fe are proportioned, low-carbon ferrochrome, high-carbon ferrochrome, ferroboron, ferrosilicon, electrolytic copper, electrolytic nickel, ferromolybdenum and pure iron are weighed, the materials are sequentially added into a vacuum induction electromagnetic furnace according to the sequence of high-to-low melting points and the principle of adding materials containing elements easy to burn and damage finally, then the temperature is raised to 2000 ℃ at the speed of 10K/s, and the temperature is preserved for 10min to completely melt the materials;
the second step is that: vacuum atomizing the molten liquid at 3MPa, drying at 80 deg.C for 2 hr, and sieving to obtain powder with particle size of 15-45 μm.
The application of the abrasion-resistant composite material for the water turbine in preparing the abrasion-resistant iron-based amorphous/boride coating comprises the following steps:
the first step is as follows: pretreating the surface of the substrate: after removing rust and oil on the surface of the matrix, performing sand blasting and coarsening on the surface of the matrix by adopting brown corundum sand with the granularity of 5-35 meshes under the air pressure of 0.7-0.8 MPa;
the second step is that: spraying on the surface of the substrate by adopting a supersonic flame spraying technology, wherein the spraying process parameters are as follows: the oxygen flow is 2000 scfh, the kerosene flow is 6.8 gph, the spraying distance is 330 mm, the carrier gas flow is 23 scfh, the rotating speed of the powder feeder is 5.5 rpm, and the moving speed of the spray gun is 280 mm/s.
Example 3
An abrasion resistant composite material for a hydraulic turbine, a method for preparing the abrasion resistant composite material for the hydraulic turbine, comprising the steps of:
the first step is as follows: according to the weight percentage of chemical components: 26wt% of Cr, 15wt% of B, 3wt% of Si, 3wt% of Cu, 5wt% of Ni, 10wt% of Mo and the balance of Fe are proportioned, low-carbon ferrochrome, high-carbon ferrochrome, ferroboron, ferrosilicon, electrolytic copper, electrolytic nickel, ferromolybdenum and pure iron are weighed, the materials are sequentially added into a vacuum induction electromagnetic furnace according to the sequence of high-to-low melting points and the principle of adding materials containing elements easy to burn and damage finally, then the temperature is raised to 2000 ℃ at the speed of 10K/s, and the temperature is preserved for 10min to completely melt the materials;
the second step is that: vacuum atomizing the molten liquid at 3MPa, drying at 80 deg.C for 2 hr, and sieving to obtain powder with particle size of 15-45 μm.
The application of the abrasion-resistant composite material for the water turbine in preparing the abrasion-resistant iron-based amorphous/boride coating comprises the following steps:
the first step is as follows: pretreating the surface of the substrate: after removing rust and oil on the surface of the matrix, performing sand blasting and coarsening on the surface of the matrix by adopting brown corundum sand with the granularity of 5-35 meshes under the air pressure of 0.7-0.8 MPa;
the second step is that: spraying on the surface of the substrate by adopting a supersonic flame spraying technology, wherein the spraying process parameters are as follows: the oxygen flow is 2000 scfh, the kerosene flow is 6.8 gph, the spraying distance is 330 mm, the carrier gas flow is 23 scfh, the rotating speed of the powder feeder is 5.5 rpm, and the moving speed of the spray gun is 280 mm/s.
The bonding strength, microhardness and abrasion volume loss rate of the abrasion-resistant iron-based amorphous/boride composite coating for the water turbine prepared in the above embodiments 1 to 3 are as follows:
| examples | Bonding strength/MPa | microhardness/HV0.3 | Abrasion volume loss ratio/(mm)3/h) |
| 1 | ≥100 | 758 | 0.05 |
| 2 | ≥100 | 832 | 0.043 |
| 3 | ≥100 | 827 | 0.048 |
Claims (3)
1. The abrasion-resistant composite material for the water turbine is characterized by comprising the following chemical components in percentage by weight: 26wt% of Cr, 5-15wt% of B, 3wt% of Si, 3wt% of Cu, 5wt% of Ni, 10wt% of Mo and the balance of Fe; the preparation method of the abrasion-resistant composite material for the water turbine comprises the following steps:
the first step is as follows: proportioning according to the weight percentage of chemical components, weighing materials of low-carbon ferrochrome, high-carbon ferrochrome, ferroboron, ferrosilicon, electrolytic copper, electrolytic nickel, ferromolybdenum and pure iron, sequentially adding the materials into a vacuum induction electromagnetic oven according to the sequence of high-to-low melting points and the principle of adding the materials containing elements easy to burn and damage, then heating to 2000 ℃, and preserving heat for 10 min;
the second step is that: vacuum atomizing the molten liquid at 3MPa, drying at 80 deg.C, and sieving to obtain powder with particle size of 15-45 μm.
2. The abrasion-resistant composite material for a water turbine according to claim 1, wherein in the first step, the temperature in the vacuum induction electromagnetic furnace is increased to 2000 ℃ at a speed of 10K/s, and the holding time is 10 min; in the second step, the drying temperature of the powder is 80 ℃, and the drying time is 2 hours.
3. Use of an erosion resistant composite material for water turbines as claimed in claim 1 for the preparation of an erosion resistant iron based amorphous/boride coating comprising the steps of:
the first step is as follows: pretreating the surface of the substrate: after removing rust and oil on the surface of the matrix, performing sand blasting and coarsening on the surface of the matrix by adopting brown corundum sand with the granularity of 5-35 meshes under the air pressure of 0.7-0.8 MPa;
the second step is that: spraying on the surface of the substrate by adopting a supersonic flame spraying technology, wherein the spraying process parameters are as follows: the oxygen flow is 2000 scfh, the kerosene flow is 6.8 gph, the spraying distance is 330 mm, the carrier gas flow is 23 scfh, the rotating speed of the powder feeder is 5.5 rpm, and the moving speed of the spray gun is 280 mm/s.
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