CN1114513C - 复合耐磨部件 - Google Patents

复合耐磨部件 Download PDF

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CN1114513C
CN1114513C CN97198472A CN97198472A CN1114513C CN 1114513 C CN1114513 C CN 1114513C CN 97198472 A CN97198472 A CN 97198472A CN 97198472 A CN97198472 A CN 97198472A CN 1114513 C CN1114513 C CN 1114513C
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ceramic
wear part
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哈伯特·弗兰西斯
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Magotteaux International SA
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Abstract

本发明涉及由铸造法制造并由金属基体构成的复合耐磨部件，其工作面包括具有良好抗磨性能的嵌入物，其特征在于，嵌入物由铸造时渗透金属液体的陶瓷芯板组成，陶瓷芯板由占重量20%到80%的氧化铝和80%到20%的氧化锆的均匀固体溶液组成。

Description

复合耐磨部件
发明的主题
本发明涉及用铸造方法制造的复合耐磨材料部件，部件由金属基体构成，其工作面包含具有良好抗磨性能的嵌入物。
背景技术
本发明尤其涉及在水泥、矿山、冶金、电站或各种类似工业中遇到的磨矿设备、破碎设备和各种磨蚀材料运输设备中使用的易磨损部件。对这些部件通常要求有很高的整体机械性能。希望这些部件有很高的耐磨性和一定的延展性，以便能具有抗冲击等机械强度和能够对其进行加工。
由于这两种性能在同一材料中很难协调一致，有人已经提出带有延伸性相当好的合金型芯的复合部件，在型芯中嵌入具有良好耐磨性的隔离嵌入物。
文献EP-A-0476496提出制造研磨滚轮的技术，滚轮的工作面配有含铬生铁的嵌入物。
众所周知，陶瓷材料具有很好的抗磨蚀性能，可以用这些材料来改善易磨损部件的抗磨蚀性能。
文献EP-A-0575685提出将陶瓷材料应用于小型耐磨损部件的失蜡精密铸造中。
该已知的方法使用蜡模，蜡模熔化得到型腔，型腔填入金属；该铸模本身由陶瓷构成，而不是通常用的砂子。
根据该文献，首先形成海绵结构的陶瓷芯板，具有所有孔之间孔孔相通的三维网结构。为了形成陶瓷芯板，往合适的铸模中注入陶瓷材料颗粒，然后，再注入有良好流动性的液体胶，例如液体树脂，凝固之后将颗粒固定，便形成陶瓷结构。陶瓷材料可由氧化铝或氧化锆组成。这种芯板在事先浸蜡之后，放在用于制作部件蜡模的铸模中。这样蜡模铸造出来，最后将蜡模浸渍在陶瓷浇注用泥浆中便形成陶瓷铸模。包含蜡模的陶瓷铸模进行加热，以便将蜡模熔化。这样蜡便从陶瓷铸模中流出，但事先在蜡模中嵌入的芯板仍然粘在陶瓷铸模的壁上。
为了在陶瓷铸模中铸造金属，陶瓷铸模一般在真空下预热到1150℃左右。
然而，这种已知的技术只限于失蜡精密铸造。此外，在金属基体和陶瓷结构之间、特别是热性能方面的相容性对于该文献提到的应用不构成问题，因为在铸造金属时，铸模和陶瓷结构被预热到高温。此外，在技术仅限于制造非常精密的部件，部件以很高的价格出售，因为失蜡铸造本身就是高成本的。
W.Gerhartz的《乌尔曼工业化学百科全书》，1985年，VCH出版社，第五版XP002023826，第5页提到了用于处理金属熔炼厂产品(钢坯和板坯)的磨削机械的以Al2O3-ZrO2为基础的构成。
本发明立足的问题
上面描述的技术不适用于在磨矿设备、破碎设备或磨蚀材料运输设备中所遇到的较大尺寸耐磨损部件的制造，在这些设备中，部件断面通常至少为25毫米，经常在40毫米以上。
此外，根据本发明技术，不可能或者至少很难考虑铸造小断面的部件，例如小于25毫米的部件，因为不论是铸模，还是陶瓷嵌入物，在铸造金属之前都不能预热到高温。
另一方面，部件通常还要经受以后的热处理。因此，在陶瓷材料和金属之间从热性能方面考虑要有一定的相容性，以防止当液体金属在陶瓷嵌入物上铸造时由于热冲击产生裂缝，并且在以后的热处理时也可能产生裂缝，这两种材料的不同膨胀系数也会产生裂缝。
此外，陶瓷材料的机械性能必须与金属的机械性能匹配，以便制造部件的性能满足特定的应用领域。
本发明的目的是制造带陶瓷嵌入物的复合耐磨部件，以令人满意的方式满足上面提到的要求。
第二个问题的提出是基于陶瓷材料厚度大于25毫米时，金属的渗透性很差这一事实。本发明的另一目的，就是为解决这个第二问题而提出复合耐磨件的特殊几何形状。本发明的主要特征
为了达到第一目的，本发明提出用传统的铸造或离心铸造来制造复合耐磨部件。这种复合耐磨件由金属基体组成，其磨损表面带有具有很好耐磨蚀性能的嵌入物，这些嵌入物由陶瓷材料制成，其本身也是复合体，由占成分重量20％到80％的氧化铝和80％到20％的氧化锆的固体溶液或均匀相组成。
此外，陶瓷材料可包含其它的氧化物，其重量比不超过3％到4％。
根据本发明的第一优选实施例，陶瓷材料成份如下：
55-60％重量的Al2O3和
38-42％重量的ZrO2。
根据另一优选实施例，陶瓷材料成份如下：
70-77％重量的Al2O3和
23-27％重量的ZrO2。
在嵌入物中陶瓷材料的含量按重量在35％和80％之间，最好在40％和60％之间，有利的是在50％左右。
这种陶瓷复合材料用陶瓷颗粒烧结而成，按照FEPA标准烧结颗粒粒度在F6到F22范围内，即直径在0.7毫米和5.5毫米之间。这些陶瓷颗粒以常规方式，用电熔法、烧结法、热抛射或其它方法制造，这些方法都能把两种组成部分熔化。
陶瓷颗粒利用一种胶烧结，其比例相对于芯板总重量而言重量不超过4％，最好重量在2％和3％之间。这种胶可以是无机的，也可以是有机的。作为例子，可以是一种硅酸盐基胶，或环氧树脂形式的胶。
本发明基于下述事实，即氧化铝(刚玉)和氧化锆性能有很大差别，可以在上述范围内进行合理选择来调整复合陶瓷件的硬度、韧性和热膨胀系数，以便把好的硬度与好的韧性结合起来，使其能应用在精密的地方，另一方面，也为了使陶瓷复合材料的膨胀系数接近所选择的铸造金属、即生铁或钢的膨胀系数(在10×10-6和11×10-6之间)。
氧化锆的优点是它的膨胀系数接近金属的膨胀系数。此外，它有很好的韧性，换句话说，它减少了破碎的危险。
至于氧化铝，它有很高的硬度。在芯板内部，在氧化铝中锆颗粒能够增加氧化铝的抗裂能力，因而具有比复合材料的每一单独成分、如ZrO2或Al2O3更高的韧性。
因此在经常强烈磨蚀的易磨部件中最好增加氧化铝的比例，但不能超过一定限度，超过这个限度，抗磨蚀性和韧性开始降低。在此情况下，最好选择陶瓷复合材料的第二个范围。
反之，对于那些经受巨大冲击或很高压力的部件，最好优先考虑膨胀系数而牺牲硬度并增加氧化锆的比例，以便减小部件中的应力，从而减小破碎的危险。
对于那些在铸造时或在以后的热处理时有发生裂缝危险的部件，最好还要增加氧化锆的比例，以便使嵌入物的膨胀系数接近金属基体的膨胀系数。
陶瓷复合嵌入物成分比例的选择，当然还要根据部件应用所要求的性能考虑铸造金属的成分。同样，铸造金属成分的选择可以与复合嵌入物的性能配合。
为了解决在陶瓷相内部液体金属不好的渗透问题，在本发明范围内提出了不同的几何形状。
当以陶瓷材料制造的芯板厚度变得很厚的特殊情况下，根据第一种实施形式，提出两块或更多块陶瓷芯板迭加在一起，而在芯板之间保留约10毫米的小空间，以便液体金属能流入。以这种方式，能在嵌入物内部大大增加陶瓷相的比例，从而解决了金属渗透性不好的问题。
根据另一实施形式，提出制造“蜂窝”结构形的芯板，该结构包括在陶瓷相内部呈现多角形或圆形的多种基本单元。构成陶瓷相的不同单元的壁厚最好在5毫米和25毫米之间变化。
在易磨损部件的磨损特别深的情况下，这种实施形式能够增加陶瓷相的量，也能解决液体金属渗透性差的问题。
其优点还在于壁厚不超过液体金属渗透的极限厚度(约25毫米)，然而高度实际上等于复合部件的高度。此外，这种“蜂窝”形的芯板的第二种形式可改善磨碎工艺。事实上，在投入使用一定时间后，在空心蜂窝的金属单元部分中填满了被磨材料，这就起到了抗磨损自保护作用。这种形式的优点是避免被磨物质形成优先磨损途径，而导致磨碎设备的流量下降。此外，根据优选的第二实施形式的“蜂窝”形结构能够减小裂缝扩展的危险，当制造部件时这种裂缝可能在渗透芯板中发展。事实上，可能产生的裂缝这时能自行封闭，而不至于扩展到整个部件。
附图说明
图1示出根据本发明的第一实施形式的复合耐磨部件。
图2示出根据本发明的第二实施形式的复合耐磨部件。
图3示出根据本发明的复合耐磨部件的一种特定应用。
实施例例1：立轴式破碎机的排出器
首先形成75％的Al2O3和23％的ZrO2的混合物，用电熔法将这两种成分熔化，形成复合颗粒，其粒度按FEPA标准在F6到F20级之间。然后将这些颗粒与一种液体胶一起注入合适形状的铸模中，在凝固之后，液体胶将颗粒固定成一整体，形成陶瓷芯板。
在此特殊例子中，建议使用图1示出的构形，两块陶瓷芯板迭加在一起，两者之间有10毫米的空间。这些芯板放在合适的铸模中，最好是砂模，然后在砂模中铸入液体生铁，生铁中包含3％的碳、26％的铬和这类合金中常用的其它少量元素。这样便制成了带陶瓷嵌入物的硬度约1600Hv、膨胀系数接近8×106的耐磨部件，而在生铁基体中保持近于750Hv的硬度。例2：破碎机的转子
如同例1一样制备陶瓷材料，但陶瓷材料成份的选择要优先考虑膨胀系数而牺牲硬度，即取40％的ZrO2和60％的Al2O3。
如果这类部件厚度特别大，则采用图2示出的“蜂窝”形结构。在此情况下，“蜂窝”形结构的单元壁厚约为20毫米，而且其高度实际上等于复合件的高度。这种结构采用锰钢制造，其成分为1％的碳、14％的锰和1.5％的钼。
这样制造的复合部件，其硬度约为1350Hv，膨胀系数接近9×106。其目的是减小这类部件在大的撞击时在部件内产生裂缝的危险。例3：拍打器
图3示出在拍打器的应用中使用的陶瓷芯板，这种结构能加强拍打器的三相磨损。陶瓷芯板是在金属相内部的单一部件。

Claims (11)

1.一种复合耐磨部件，由传统铸造法或离心铸造法制造并由一金属基体构成，其工作面包括具有良好抗磨性能的嵌入物，其特征在于，嵌入物由在铸造时渗入液体金属的陶瓷芯板构成，该陶瓷芯板由占成分重量20％到80％的Al2O3和80％到20％的ZrO2的均匀固体溶液组成。
2.根据权利要求1所述的复合耐磨部件，其特征在于，陶瓷材料包括55％到60％重量的Al2O3和38％到42％重量的ZrO2。
3.根据权利要求1所述的复合耐磨部件，其特征在于，陶瓷材料包括70％到77％重量的Al2O3和23％到27％重量的ZrO2。
4.根据权利要求1所述的复合耐磨部件，其特征在于，在嵌入物中陶瓷材料的含量按重量在35％和80％之间，优选的是在40％和60％之间，最好为50％左右。
5.根据权利要求1所述的复合耐磨部件，其特征在于，嵌入物由复合陶瓷颗粒块组成，按照FEPA标准，其颗粒度在F6到F22的范围内。
6.根据权利要求1所述的复合耐磨部件，其特征在于，陶瓷颗粒用电熔法、烧结法、热抛射法或者其它方法制造。
7.根据权利要求1所述的复合耐磨部件，其特征在于，陶瓷颗粒用一种无机或有机胶固化，以便制成陶瓷芯板。
8.根据权利要求1所述的复合耐磨部件，其特征在于，陶瓷颗粒借助一种胶固化，芯板所含的胶不超过4％。
9.一种复合耐磨部件，用铸造法制造并由至少包括一个陶瓷芯板的金属基体组成，其特征在于，至少两个陶瓷芯板并列设置，中间留有约10毫米的空隙，以便使金属进入。
10.根据权利要求1所述的复合耐磨部件，其特征在于，陶瓷芯板呈蜂窝形结构，其不同单元在陶瓷相内呈多角形或圆形。
11.根据权利要求10所述的复合耐磨部件，其特征在于，组成陶瓷相的不同单元的壁厚在5毫米到25毫米之间。
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CZ111699A3 (cs) 1999-08-11
PL332578A1 (en) 1999-09-27
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WO1998015373A1 (fr) 1998-04-16
HU224208B1 (hu) 2005-06-28
AU723329B2 (en) 2000-08-24
CN1232416A (zh) 1999-10-20
SK40299A3 (en) 1999-11-08
DE69702988D1 (de) 2000-10-05
EE9900139A (et) 1999-12-15
JP2001504036A (ja) 2001-03-27
BR9712188A (pt) 2000-01-25
US20020136857A1 (en) 2002-09-26
AU4552997A (en) 1998-05-05
ID17782A (id) 1998-01-29
UA46124C2 (uk) 2002-05-15
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DE69702988T2 (de) 2001-03-01
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US6399176B1 (en) 2002-06-04
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CA2266475A1 (fr) 1998-04-16
CZ294041B6 (cs) 2004-09-15
PL189446B1 (pl) 2005-08-31
US6520241B2 (en) 2003-02-18
HUP9904505A3 (en) 2000-06-28
HUP9904505A2 (hu) 2000-05-28
ATE195895T1 (de) 2000-09-15
EP0930948B1 (fr) 2000-08-30
MY128314A (en) 2007-01-31
EP0930948A1 (fr) 1999-07-28
WO1998015373A8 (fr) 1999-11-11
USRE39998E1 (en) 2008-01-08
PT930948E (pt) 2001-01-31

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