CN111519070A - High-chromium-nickel-base superalloy, diesel engine air valve and diesel engine air valve manufacturing process - Google Patents
High-chromium-nickel-base superalloy, diesel engine air valve and diesel engine air valve manufacturing process 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
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/08—Upsetting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/20—Making machine elements valve parts
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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
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- C22C30/02—Alloys containing less than 50% by weight of each constituent containing copper
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Abstract
The invention discloses a high chromium nickel-based superalloy, a diesel engine air valve and a diesel engine air valve manufacturing process, wherein the high chromium nickel-based superalloy comprises the following necessary elements in percentage by mass: 35-45% of Cr, 1.0-5% of Al, 0.2-15% of Fe and 0.1-10% of Co; the balance of Ni and impurities, or Ni, impurities and optional elements. Diesel engine valves are made of high chromium nickel base superalloys. The manufacturing process of the diesel engine air valve adopts an electric upsetting-forging forming process, and applies electric upsetting forming process parameters in a high-order subsection dynamic loading mode in the electric upsetting process; the electric upsetting forming process parameters comprise electric upsetting current; high-order segmentation dynamic loading mode: the electric upsetting stroke is subdivided into more than 10 sections, and corresponding electric upsetting forming technological parameters are loaded for each section of electric upsetting stroke, so that the variation amplitude of the electric upsetting forming technological parameters is reduced. The invention can improve the hot processing performance of the nickel-based superalloy, promote the uniform grain refinement and the surface ripple improvement of the electric upsetting workpiece, and improve the hardness, high temperature resistance, corrosion resistance and creep resistance of the diesel engine air valve.
Description
Technical Field
The invention belongs to the technical field of metal plastic forming, and particularly relates to a large-size diesel engine air valve made of a high-chromium-nickel-based superalloy material and a manufacturing method thereof.
Background
Ocean transportation is one of the most important transportation modes in international commodity exchange, and the proportion of cargo transportation volume in all international cargo transportation volume is more than 80%. In order to reduce the operation cost, various transport ships are becoming large-scale and huge, and the single-cylinder power and the single-machine power of the marine diesel power low-speed machine are continuously developed to be strengthened and deep. Meanwhile, a supercharging technology and an exhaust gas recirculation technology which correspond to high-efficiency combustion economy and low-emission ecology required by a marine main engine enable a combustion chamber of a diesel engine to be in a high-load strengthening state, so that an exhaust system is in a severe environment with higher temperature, higher corrosivity, higher pressure and higher scouring force during service, and the reliability and the safety of a prime motor are endangered.
The thermal load borne by the air valve in the exhaust system in the currently-appearing energy-efficient marine diesel-powered low-speed machine has reached or even exceeded the limit of the Ni80A nickel-based superalloy materials (Cr: 20.87%, Fe 1.26%, Al 0.68%, Mn: 0.63%, Ti: 2.07%, Si: 0.55%, C: 0.069%, and the balance Ni) designed by the main engine plant, and the heat resistance, corrosion resistance and thermal mechanical fatigue resistance of the nickel-based superalloy materials for these components need to be further improved to realize the high heat efficiency and durability of the low-speed machine.
For the Ni80A nickel-based superalloy material, the process parameter range of electric upsetting forming is narrow, the electric upsetting forming is extremely sensitive to temperature, dynamic hardening, cracks and the like are easy to occur when the electric upsetting parameters are not matched, and further wave defects are deepened (shown by an area A in figure 1), so that the performance of the Ni80A nickel-based superalloy gas valve is difficult to improve from the gas valve manufacturing process.
Disclosure of Invention
Aiming at the technical defects, the invention provides a high-chromium nickel-based superalloy, which solves the technical problem that the hot workability of the nickel-based superalloy in the prior art needs to be improved.
In order to solve the technical problems, the technical scheme of the invention is as follows: a high chromium nickel base superalloy containing the following essential elements in mass percent: 35-45% of Cr, 1.0-5% of Al, 0.2-15% of Fe and 0.1-10% of Co; the balance of Ni and impurities, or Ni, impurities and optional elements.
Preferably, the optional elements are any one or combination of the following elements in percentage by weight: less than or equal to 5 percent of Si, less than or equal to 0.01 percent of B, less than or equal to 0.1 percent of C, less than or equal to 5 percent of Cu, less than or equal to 0.1 percent of Ti, less than or equal to 0.1 percent of Nb, less than or equal to 0.1 percent of Ta, less than or equal to 0.1 percent of V, less than or equal to 0.2 percent of Mn, 0.01 to 0.5 percent of Ce0.01, 0.01 to 0.2 percent of S.
The invention also provides a diesel engine air valve made of the high-chromium-nickel-based superalloy.
The invention also provides a manufacturing process of the diesel engine air valve, which adopts an electric upsetting-forging forming process, namely, after forming the electric upsetting garlic head by electric upsetting, die forging forming is carried out, and electric upsetting forming process parameters are applied by adopting a high-order subsection dynamic loading mode in the electric upsetting process; the electric upsetting forming process parameters comprise electric upsetting current; the high-order subsection dynamic loading mode comprises the following steps: the electric upsetting strokes are subdivided into more than 10 sections, and corresponding electric upsetting forming technological parameters are loaded for each section of electric upsetting stroke, so that the variation amplitude of the electric upsetting forming technological parameters of the adjacent electric upsetting strokes in the whole electric upsetting forming technological parameter range is reduced.
Preferably, the electric upsetting process in the high-order subsection dynamic loading mode is simulated in advance through finite elements, an electric upsetting forming process parameter loading scheme meeting the electric upsetting shape requirement and the grain fineness requirement is preferably selected, and the electric upsetting forming process parameter loading scheme is composed of electric upsetting forming process parameters of each section of electric upsetting stroke.
Preferably, the parameters of the electric upsetting forming process further comprise preheating time, preheating temperature, upsetting force, anvil retreating speed, clamping length and clamping force; the number of the sections of the upsetting stroke is more than 40; applying electric upsetting forming process parameters through a high-order subsection dynamic loading mode to control the whole-process electric upsetting temperature to be 1100-1000 ℃.
Preferably, the electric upsetting rod material is subjected to end face treatment before electric upsetting: the end faces are rounded or beveled.
Preferably, the die used for die forging forming comprises an upper die and a lower die; the lower die is used for forming the outline dimension of the diesel engine air valve; the upper die is used for increasing the deformation of the central area of the electric upsetting garlic and promoting the central area of the electric upsetting garlic to be dynamically recrystallized; the upper die comprises a flat die, a male die and a female die; and selecting different types of upper dies or upper die combinations according to the external dimension of the diesel engine air valve to match with the lower die for die forging forming.
Preferably, the raw material of the diesel engine gas valve manufacturing process adopts the electric upsetting rod material made of the high-chromium nickel-based superalloy of the invention.
Compared with the prior art, the invention has the advantages that:
1. the high-chromium nickel-based superalloy increases the content of Cr, increases the content of a lamellar gamma' phase and an alpha-Cr phase which is discontinuously precipitated, and has higher hardness and high-temperature creep resistance, and the hardness can reach more than 650 HV. Meanwhile, after Al element is added into the high Cr concentration material, a gamma '(Ni 3Al4) phase can be precipitated from a gamma phase matrix, and the gamma' (Ni3Al4) phase is a continuous precipitation strengthening phase and can also improve the high-temperature creep resistance of the alloy.
2. The addition of Co element is beneficial to the alloy to form a continuous protective oxide film in the hot corrosion incubation period, so that the hot corrosion resistance of the alloy is improved; in the hot corrosion diffusion period, Co element can also effectively prevent the diffusion of sulfur in the alloy, thereby further improving the corrosion resistance of the alloy. Co element is also a solid solution element in the nickel-based alloy, and can improve the strength of the alloy through a solid solution strengthening mode.
3. The addition of optional elements can further improve the alloy properties: ti and Nb elements can form a gamma' precipitation strengthening phase with Ni, and better high-temperature strength can be obtained. Meanwhile, Nb has good strong heat property. The element C is an indispensable element in steel, and is also a carbide-forming element with high strength. In general, C in heat-resistant steel precipitates as carbide during aging, and improves mechanical properties. Si is a beneficial element for resisting high-temperature corrosion. Can form a SiO2 dense oxide film with good protection at high temperature, and simultaneously, Si and Al are alloyed together to obviously improve the high-temperature oxidation resistance. The B element can improve the hardenability and high-temperature strength of the steel and also has the function of strengthening a grain boundary. The Cu element improves the corrosion resistance. Ta element is used as a solid solution strengthening agent in the alloy and can inhibit the vulcanization effect together with Ti and Cr. The element V is a forming element of a strong carbide, and can improve the heat strength of the heat-resistant steel. It also has refining effect on crystal grains, and can obviously improve the plasticity of the hot working process. Ce is rare earth element, which can improve the physical and chemical properties of the alloy and improve the high-temperature mechanical properties of the alloy. Mn is a good deoxidizer and desulfurizer, and can improve hot workability. Form a solid solution with iron, and can increase strength and hardness. S and P are inevitable impurity elements.
4. The high chromium-nickel-based superalloy of the invention can reduce deformation resistance, has more uniform deformation, good thermoplastic formability, less influence of temperature change on stress change, wider range of electric upsetting process parameters and improved hot-working performance.
5. By adopting the high-order subsection dynamic loading mode, the electric upsetting temperature is not increased or reduced sharply, the change of the electric upsetting temperature is relatively stable, and the change degree of the deformation resistance (stress) of the electric upsetting material along with the temperature change is smaller, so that the formation of surface ripples is reduced.
6. The excessive temperature easily causes the crystal grains of the electric upsetting piece to be thick, and is not beneficial to the uniform refinement of the crystal grains, but the excessive temperature causes the surface ripple defects of the electric upsetting piece to be aggravated, in order to balance the crystal grains and the ripples, the electric upsetting process in a high-order segmented dynamic loading mode is simulated in advance through finite elements, and an electric upsetting forming process parameter loading scheme meeting the requirements of the electric upsetting shape and the uniform fineness of the crystal grains is preferably selected.
7. The electric upsetting temperature is comprehensively influenced by electric upsetting process parameters, wherein the most obvious influencing factor is electric upsetting current, and the larger the current is, the higher the temperature is, the larger the corresponding crystal grains are. In order to satisfy the electric upsetting formation and the grain refinement simultaneously, the current tends to increase and decrease, and the corresponding electric upsetting temperature is a process from low temperature to high temperature and then to low temperature. On the contrary, if the electric upsetting temperature is always increased, the coarsening of the crystal grains is very serious, and the performance of the valve is reduced.
8. The end face treatment can reduce the material of the edge area of the end face, and is beneficial to concentrated transmission of upsetting force to the central area of the electric upsetting garlic, so that the end face depression of the garlic is improved, the current density of the concave part in the center is reduced due to the improvement of the end face depression of the garlic, the temperature of the central area of the electric upsetting garlic is reduced, and the phenomenon that grains are thick easily generated in the central area is improved. Along with the reduction of the material of the edge area of the end face, the temperature of the edge area of the end face is increased, and the thermoplastic deformation of the edge area of the end face is easier, so that the surface ripple defect is reduced; meanwhile, the temperature difference between the edge area and the central area of the end face is reduced, and the grain size distribution is more uniform.
9. Because the air valve of the diesel engine is a component with a large section change rate, the internal deformation is uneven because the component is large, the fine grain degree of internal dynamic recrystallization is easily uneven, the crystal grains in the central area of the electric upsetting garlic are relatively thick, and the heat preservation treatment (particularly secondary heating) after the electric upsetting easily causes the crystal grains to grow again and coarsen.
10. The high-chromium-nickel-based superalloy of the invention is combined with the high-order subsection dynamic loading mode of the invention, and as the deformation resistance of the material is smaller, the influence of the temperature change on the stress change is smaller, under the same electric upsetting temperature range, compared with the existing material, the high-chromium-nickel-based superalloy can reduce the generation of surface ripples, and the influence of the temperature change on the stress change is smaller, so that the high-chromium-nickel-based superalloy can adapt to the whole electric upsetting process parameter range with a wider range, realize the high-order subsection dynamic loading, and further reduce the surface ripples. However, since the range of the whole-process electric upsetting process parameter of the Ni80A nickel-based super-alloy formable process is narrow, it is difficult to realize high-order segmented dynamic loading in the narrow whole-process electric upsetting process parameter range because the parameter variation range is too low to exceed the controllable range.
Drawings
FIG. 1 is a schematic diagram of surface ripple defects of an electric upsetting member in the prior art;
FIG. 2 is a graph of stress-strain test results for a prior art Ni80A nickel-based superalloy material;
FIG. 3 is a graph of the stress-strain test results for a high chromium nickel-based superalloy as in example 1;
FIG. 4 is a schematic view showing the shape of the electric heading member after completion of electric heading in example 1;
FIG. 5 is a schematic view of a swaging operation;
FIG. 6 is a schematic view of a diesel valve after die forging;
FIG. 7 is a graph of the stress-strain test results for a high chromium nickel based superalloy as in example 2;
FIG. 8 is a graph showing the shape of an electrically upset garlic bulb in the high-order staged dynamic loading mode of the high chrome-nickel based superalloy in example 2;
FIG. 9 is the shape of the electrically upset garlic bulb in the low order staged dynamic loading mode of the high chrome nickel base superalloy of example 2.
Detailed Description
Example 1
The high chromium nickel-based superalloy in this example comprises the following essential elements in mass percent: 35% of Cr, 1.0% of Al, 0.2% of Fe and 0.1% of Co; the balance being Ni and impurities.
The high-chromium nickel-based superalloy in this example was subjected to stress-strain tests at different temperatures and strain rates, and the test results are shown in fig. 3. The stress-strain test results for the prior art Ni80A nickel-based superalloy material are shown in fig. 2.
As can be seen by comparing FIG. 2 with FIG. 3, the high-chromium nickel-base superalloy of the present example exhibited two strain rates of equal magnitude (A), (B), (C), (D
And
) The stress of the alloy is less than the stress value of Ni80A at the same temperature (950 ℃, 1020 ℃, 1100 ℃, 1175 ℃ and 1250 ℃); in the process of electric upsetting forming, the deformation resistance is small, the deformation is more uniform, and the plastic forming is better.
Meanwhile, according to the curve, the stress of the Ni80A alloy is greatly influenced by the temperature, particularly in the temperature range of 950-1025 ℃, and the temperature is just in the temperature range of the electric upsetting center and the surface layer, so that dynamic hardening is easily caused, and the corrugation defect is deepened. The stress of the high-chromium-nickel-base superalloy in the embodiment is less affected by temperature, for example: in FIG. 3(a), the stress variation range of the high-chromium nickel-based superalloy ranges from 0MPa to 200MPa within the temperature variation range of 950 ℃ to 1250 ℃, whereas in FIG. 2(a), the stress variation range of the Ni80A nickel-based superalloy ranges from 0MPa to 800MPa within the same temperature variation range of 950 ℃ to 1250 ℃, so that the range of the electric upsetting process parameter for the high-chromium nickel-based superalloy is wider compared with that of the Ni80A alloy.
Room temperature mechanical property tests were performed on the high chromium nickel-based superalloy of this example, and the test results are shown in table 1, and the room temperature mechanical property test results of the Ni80A nickel-based superalloy material of the prior art are shown in table 2.
Comparing table 1 and table 2, it can be seen that the strength and hardness of the high chromium-nickel base superalloy in this example are both higher than those of Ni80A alloy, and the mechanical properties are better.
TABLE 1
TABLE 2
The high-chromium nickel-base superalloy in the embodiment is adopted to manufacture an electric upsetting rod material to manufacture a diesel engine air valve, the diameter of a rod blank of 67mm is taken as an example, in order to ensure that the end face of a garlic bulb does not have pit defects, the end face of the rod blank is subjected to fillet treatment, and the fillet size is R16 mm; processing the end face shape of the rod blank: the method comprises the following steps of chamfering, chamfering and mutual matching of the chamfering and the chamfering, and end face treatment can be omitted. In order to ensure that the shape in the electric upsetting process is smooth and avoid the defects of folding and grooves, the rod blank is subjected to fillet treatment, and the size of the fillet is in proportional relation with the diameter of the rod blank.
The manufacturing process of the diesel engine air valve adopts an electric upsetting-forging forming process, namely, after an electric upsetting rod material is electrically upset to form an electric upsetting garlic head, die forging forming is carried out, and a high-order subsection dynamic loading mode is adopted in the electric upsetting process to apply electric upsetting forming process parameters; the electric upsetting forming process parameters comprise electric upsetting current; high-order segmentation dynamic loading mode: the electric upsetting strokes are subdivided into 10 sections (the highest 100 sections), and corresponding electric upsetting forming technological parameters are loaded for each section of electric upsetting stroke, so that the variation amplitude of the electric upsetting forming technological parameters of the adjacent electric upsetting strokes in the whole electric upsetting forming technological parameter range is reduced.
The method comprises the steps of simulating an electric upsetting process in a high-order subsection dynamic loading mode through finite elements in advance, and preferably selecting an electric upsetting forming process parameter loading scheme meeting the requirements of electric upsetting shape and grain fineness, wherein the electric upsetting forming process parameter loading scheme is composed of electric upsetting forming process parameters of each section of electric upsetting stroke.
The parameters of the electric upsetting forming process comprise preheating time, preheating temperature, upsetting force, anvil retreating speed, clamping length and clamping force.
Preheating time and preheating temperature: in the early stage of electric upsetting, the temperature is low, the blank is long, the upsetting force is large, instability is easy to occur, the blank is heated abnormally, and the subsequent electric upsetting process is influenced. Therefore, a certain current self-resistance preheating time and a certain preheating temperature need to be set. According to the specifications of equipment and an air valve, the preheating time is set to 32s, the preheating temperature is about 465 ℃, the initial value of the loading current is set to 15KN, and the temperature range of the whole electric upsetting (excluding the preheating stage) is 1100-1000 ℃.
Clamping length: the diameter of the rod blank is generally 0.85-1.15 times that of the rod blank according to the setting of the electric upsetting condition of the air valve.
Anvil retreat speed: in order to ensure a proper height-diameter ratio, the retreating speed of the anvil cannot be too high, and can be set according to equipment conditions, and is generally 0.2-0.3 mm/s; and a high-order subsection dynamic loading mode can be adopted according to the electric upsetting condition, and the retreating speed of the anvil with variable loading is set.
Clamping force: the clamping force is set according to the cross section area of the rod blank, and generally, the larger the diameter of the rod blank is, the larger the clamping force is; but not too large, which would prevent the formation of the electric upset. The clamping force does not hinder the electric upsetting forming in the implementation.
Initial heading force value: and (3) performing flexibility checking on the rod blank to ensure that the rod blank is not bent and unstable in the initial stage of electric upsetting, and setting the initial value of the upsetting force to be 480 KN.
The electric upsetting temperature is controlled by controlling the electric upsetting current, and the technological parameter matching contents are different for low-speed diesel engine air valves with different specifications and need to be set according to simulation and actual conditions. Between air valves with different specifications, the initial value of the heading force is obtained according to the cross-sectional area ratio of the rod blank, the initial value of the loading current is determined according to the end face length of the rod blank, the preheating time and the temperature, and the end face length of the rod blank refers to the length of the original rod blank after the end face is processed.
Under the condition that the height-diameter ratio is less than 3.2, the electric upsetting temperature is regulated and controlled through dynamic loading parameters, so that the temperature in the whole electric upsetting process is controlled between 1000 ℃ and 1100 ℃, and the requirement of grain structure is met. The higher the temperature is, the more obvious the coarsening of the crystal grains is, and the lower the temperature is, the more easily the crystal grains meet the requirements. Finally, the shape and the structure of the electric upsetting meet the requirements at the same time.
After the finite element simulation is completed, the electric upsetting forming shape and the structure are controlled, and after the actual requirements are met, an electric upsetting blank forming test is carried out on the electric upsetting blank forming structure.
The shape of the electric upsetting piece after the electric upsetting is finished is shown in fig. 4, and no pit folding defects exist on the surface A. Wherein L1 is the length of the electric upsetting garlic; d1 and D2 are diameters of electric upsetting garlic. The average diameter of the garlic is as follows: (D1+ D2)/2; the height-diameter ratio is as follows: L1/(D1+ D2)/2. The high-chromium-nickel-based superalloy meets the requirements of height-diameter ratio, crystal grains and surface corrugation by combining a high-order subsection dynamic loading mode.
The high-order subsection dynamic loading mode means that parameters such as heading force, loading current, anvil retreating speed and the like have a large number of subsections in the electric upsetting process, and the material has a large number of parameter change times and a small parameter change amplitude in a short electric upsetting stroke. The high-order subsection dynamic loading mode subdivides the electric upsetting stroke, and the variation amplitude of parameters such as upsetting force, loading current and the like under each section of electric upsetting displacement is reduced, so that the technological parameters tend to be stable. Meanwhile, the wave defect on the surface of the electric upsetting piece is improved to a certain extent due to small parameter change amplitude. In the whole electric upsetting process, the temperature is not sharply increased or sharply reduced and is in a relatively stable temperature range, so that the grain size of the electric upsetting piece tends to be uniformly refined.
Table 3 is a comparison of two loading modes, wherein the dynamic loading mode with the low-order segmentation has the segmentation times of 10
TABLE 3
| Load mode | Low-order subsection dynamic loading mode | High-order subsection dynamic loading mode |
| Number of stages of process parameters | Chinese character shao (a Chinese character of 'shao') | Multiple purpose |
| Amplitude of variation of parameter | Big (a) | Small |
| Surface wave of electric upsetting piece | Is obvious | Is not obvious |
| Diameter variation of electric upset | Big (a) | Small |
| Aspect ratio and grain size | Difficult to coordinate | Easy coordination |
| Stability of parameters | Instability of the film | Stabilization |
| Difficulty of parameter matching | Difficulty in | Is easy to use |
| D1 | 148.3 | 146.4 |
| D2 | 130.6 | 135.2 |
| L1 | 390.2 | 384.7 |
| Height to diameter ratio | 2.80 | 2.73 |
| Die | 148.2 | 114.6 |
The electric upsetting piece after the electric upsetting is finished needs to be insulated through a heating furnace, the initial forging temperature of the electric upsetting piece is ensured, and preparation is made for die forging forming. Through setting up heat preservation time and temperature, can heat the heat preservation to the electric upset piece direct heating after the electric upset is accomplished, also can wait that it reheats the heat preservation after cooling down. The latter is longer than the former. After the electric upsetting is finished, a thermoelectric upsetting piece can be used for heat preservation or a cold electric upsetting piece can be used for heat preservation, and the heat preservation of the thermoelectric upsetting piece is realized by immediately heating and preserving the thermoelectric upsetting piece after the electric upsetting is finished; the heat preservation of the cold electric upsetting piece is that the heat preservation is carried out after the air cooling is finished. The heat preservation temperature is 1020 and 1100 ℃; the heat preservation time of the thermoelectric upsetting piece is 30min, and the heat preservation time of the cold electric upsetting piece is 45-60 min.
After the electric upsetting piece is subjected to heat preservation in the heating furnace, the electric upsetting piece needs to be subjected to die forging forming immediately, and the die forging forming is shown in fig. 5. Wherein, 1 is an electric upsetting piece, and 2 is an upper die; and 3, a lower die. The forging temperature and technological parameters are set according to the material, the forming condition of the electric upsetting piece and the requirements. And performing die forging forming on the electric forging piece with the initial forging temperature of 1020-1110 ℃ by a 7000T oil press. The mold of the oil press is divided into an upper mold and a lower mold, the upper mold is a special mold and comprises three pairs, namely a flat mold, a male mold and a female mold, and the lower mold is a mold which meets the process design requirement and is the overall dimension of the low-speed diesel engine air valve. The upper die can be rapidly replaced and randomly combined and matched to complete the die forging forming of low-speed diesel engine air valves with different specifications. The specific combination method is referred to Chinese patent 'nickel-base superalloy marine low-speed diesel engine air valve blank forming process (CN 111097868A)'.
The diesel valve formed by the die forging was shaped as shown in fig. 6, and crystal grains in the central region B of the disk portion of the diesel valve were refined. The mechanical property of the material can be improved by grain refinement. When plastic deformation occurs, the fine grains can disperse external force, so that the plastic deformation is uniform and the stress concentration is small. Correspondingly, the finer the grains, the better the strength, hardness, plasticity and toughness of the material. Further, the finer the crystal grains, the larger the grain boundary area, and the more tortuous the grain boundary, the more unfavorable the crack propagation. On the contrary, if the grain size of the gas valve is too large or the grain size distribution is not uniform, the intergranular cracks of the material are accelerated to spread during the service process, and the toughness and creep resistance of the material are reduced.
The improvement of the surface corrugation can reduce the folding defect and the deflection instability tendency of the gas valve electric upsetting blank during die forging forming. If the garlic surface waves are serious in the electric upsetting forming process, the metal flow direction of the electric upsetting blank is unreasonable during die forging, the folding defect can be generated, and the performance and the service life of the air valve are reduced. By improving the surface corrugation, the folding defect and the deflection instability tendency of the gas valve electric upsetting blank during die forging forming can be reduced.
Example 2
This example differs from example 1 in the composition of the high chrome-nickel based superalloy and the number of segments in the high order segmented dynamic loading mode. In the embodiment, the components of the high-chromium nickel-based superalloy are 45% of Cr, 5% of Al, 15% of Fe and 10% of Co; the balance being Ni and impurities. The number of the segments of the high-order segmented dynamic loading mode is 40.
The high-chromium nickel-based superalloy of the present example was subjected to stress-strain testing at different temperatures and strain rates, and the test results are shown in fig. 7. The stress-strain test results for the prior art Ni80A nickel-based superalloy material are shown in fig. 2.
As can be seen by comparing FIG. 2 with FIG. 7, the high-chromium nickel-base superalloy of the present example exhibited two strain rates of equal magnitude (A), (B), (C), (D
And
) And the stress of the alloy is less than the stress value of Ni80A at four same temperatures (950 ℃, 1100 ℃, 1150 ℃ and 1250 ℃); in the process of electric upsetting forming, the deformation resistance is small, the deformation is more uniform, and the thermoplastic forming is better.
Meanwhile, according to the curve, the stress of the Ni80A alloy is greatly influenced by the temperature, particularly in the temperature range of 950-1025 ℃, and the temperature is just in the temperature range of the electric upsetting center and the surface layer, so that dynamic hardening is easily caused, and the corrugation defect is deepened. The stress of the high-chromium-nickel-base superalloy in the embodiment is less affected by temperature, for example: in FIG. 7(a), the stress variation range of the high-chromium nickel-based superalloy ranges from 60 MPa to 225MPa within the temperature variation range of 950 ℃ to 1250 ℃, whereas in FIG. 2(a), the stress variation range of the Ni80A nickel-based superalloy ranges from 0MPa to 800MPa within the same temperature variation range of 950 ℃ to 1250 ℃, so that the range of the electric upsetting process parameter for the high-chromium nickel-based superalloy is wider compared with that of the Ni80A alloy.
Room temperature mechanical property tests were performed on the high chromium nickel-based superalloy of this example, and the test results are shown in table 4, and the room temperature mechanical property test results of the Ni80A nickel-based superalloy material of the prior art are shown in table 2.
TABLE 4
Comparing table 4 and table 2, it can be seen that the strength and hardness of the high chromium-nickel base superalloy in this example are both higher than those of Ni80A alloy, and the mechanical properties are better.
The high-chromium nickel-based superalloy in the embodiment is subjected to electric upsetting finite element simulation, the shape of an electric upsetting garlic head in an electric upsetting process in a high-order sectional dynamic loading mode is shown in fig. 8, and the shape of the electric upsetting garlic head in the electric upsetting process in a low-order sectional dynamic loading mode is shown in fig. 9. Comparing fig. 8 and fig. 9, it can be known that the electric upsetting garlic head under the high-order subsection dynamic loading mode is formed smoothly without pit folding defects.
In this embodiment, the number of segments in the high-order segmented dynamic loading mode is 40, the number of segments in the low-order segmented dynamic loading mode is 10, and table 5 is a comparison between the two loading modes:
TABLE 5
Examples 3 to 5
TABLE 6 comparison of high-chromium nickel-based superalloy formulations
Combination 1: 0.08 percent of C; si: 0.33 percent; b: 0.01 percent; cu: 0.36 percent; ti: 0.08 percent; nb: 0.06 percent; ta: 0.04 percent; v: 0.03 percent; mn: 0.1 percent; 0.2 percent of Ce;
and (3) combination 2: 0.08 percent of C; si: 0.42 percent; b: 0.01 percent; cu: 0.34 percent; ti: 0.1 percent; nb: 0.1 percent; ta: 0.04 percent; v: 0.07 percent; mn: 0.2 percent; 0.4 percent of Ce;
and (3) combination: 0.1 percent of C; si: 0.36 percent; b: 0.01 percent; cu: 0.33 percent; ti: 0.08 percent; nb: 0.06 percent; ta: 0.08 percent; v: 0.05 percent; mn: 0.16 percent; 0.35 percent of Ce;
wherein, the addition of optional elements can further improve the alloy performance: ti and Nb elements can form a gamma' precipitation strengthening phase with Ni, and better high-temperature strength can be obtained. Meanwhile, Nb has good strong heat property. The element C is an indispensable element in steel, and is also a carbide-forming element with high strength. In general, C in heat-resistant steel precipitates as carbide during aging, and improves mechanical properties. Si is a beneficial element for resisting high-temperature corrosion. Can form a SiO2 dense oxide film with good protection at high temperature, and simultaneously, Si and Al are alloyed together to obviously improve the high-temperature oxidation resistance. The B element can improve the hardenability and high-temperature strength of the steel and also has the function of strengthening a grain boundary. The Cu element improves the corrosion resistance. Ta element is used as a solid solution strengthening agent in the alloy and can inhibit the vulcanization effect together with Ti and Cr. The element V is a forming element of a strong carbide, and can improve the heat strength of the heat-resistant steel. It also has refining effect on crystal grains, and can obviously improve the plasticity of the hot working process. Ce is rare earth element, which can improve the physical and chemical properties of the alloy and improve the high-temperature mechanical properties of the alloy. Mn is a good deoxidizer and desulfurizer, and can improve hot workability. Form a solid solution with iron, and can increase strength and hardness. The inevitable impurity elements are mainly S and P.
Examples 3 to 5
TABLE 7 comparison of high chromium nickel base superalloy Performance parameters
In conclusion, compared with the 3J40 alloy and the Ni80A alloy, the novel nickel-based superalloy material contains high-content Cr element, and increases the content of lamellar gamma' phase and alpha-Cr phase which is discontinuously precipitated, so that the alloy has higher hardness and high-temperature creep resistance, and the hardness can reach more than 650 HV. Meanwhile, after Al element is added into the high Cr concentration material, a gamma '(Ni 3Al4) phase can be precipitated from a gamma phase matrix, and the gamma' (Ni3Al4) phase is a continuous precipitation strengthening phase and can also improve the high-temperature creep resistance of the alloy. In addition, due to the addition of Co element, the alloy is beneficial to forming a continuous protective oxide film in the hot corrosion incubation period, and the hot corrosion resistance of the alloy is provided; in the hot corrosion diffusion period, the cobalt can also effectively prevent the diffusion of sulfur in the alloy, thereby further improving the corrosion resistance of the alloy. Co element is also a solid solution element in the nickel-based alloy, and can improve the strength of the alloy through a solid solution strengthening mode. Therefore, compared with the common Ni-Cr alloy, the gas valve manufactured by the new material has higher hardness and better high temperature resistance, corrosion resistance and creep resistance.
The high chromium nickel-based superalloys described in examples 3-5 were used in the manufacture of diesel valves in the same manner as in examples 1 and 2 and will not be described in detail herein.
Claims (10)
1. A high chromium nickel base superalloy, comprising the following essential elements in mass percent: 35-45% of Cr, 1.0-5% of Al, 0.2-15% of Fe and 0.1-10% of Co; the balance of Ni and impurities, or Ni, impurities and optional elements.
2. The high chromium nickel base superalloy according to claim 1, wherein the optional element is any one or combination of the following elements in weight percent: less than or equal to 5 percent of Si, less than or equal to 0.01 percent of B, less than or equal to 0.1 percent of C, less than or equal to 5 percent of Cu, less than or equal to 0.1 percent of Ti, less than or equal to 0.1 percent of Nb, less than or equal to 0.1 percent of Ta, less than or equal to 0.1 percent of V, less than or equal to 0.2 percent of Mn, 0.01 to 0.5 percent of Ce, 0.01 to 0.2 percent of S and 0..
3. A diesel valve characterized by: made of the high chromium nickel base superalloy as claimed in claim 1 or 2.
4. A diesel engine air valve manufacturing process, adopt the electric upsetting-forge the shaping process, namely after the electric upsetting forms the garlic bulb, carry on the die forging and shape, characterized by, adopt the high-order time to segment the dynamic loading mode and exert the shaping technological parameter of electric upsetting in the electric upsetting process; the electric upsetting forming process parameters comprise electric upsetting current; the high-order subsection dynamic loading mode comprises the following steps: the electric upsetting strokes are subdivided into more than 10 sections, and corresponding electric upsetting forming technological parameters are loaded for each section of electric upsetting stroke, so that the variation amplitude of the electric upsetting forming technological parameters of the adjacent electric upsetting strokes in the whole electric upsetting forming technological parameter range is reduced.
5. The diesel engine air valve manufacturing process according to claim 4, characterized in that an electric upsetting process in a high-order segmented dynamic loading mode is simulated in advance through finite elements, an electric upsetting forming process parameter loading scheme meeting the electric upsetting shape requirement and the grain fineness requirement is optimized, and the electric upsetting forming process parameter loading scheme is composed of electric upsetting forming process parameters of each section of electric upsetting stroke.
6. The diesel valve manufacturing process according to claim 4, wherein the electric upsetting rod material is subjected to end face treatment before electric upsetting: the end faces are rounded or beveled.
7. The diesel valve manufacturing process according to claim 4 or 5, wherein the electrical upsetting forming process parameters further comprise preheating time, preheating temperature, heading force, anvil retreating speed, clamping length and clamping force; the number of the electric upsetting stroke is more than 40; applying electric upsetting forming process parameters through a high-order subsection dynamic loading mode to control the whole-process electric upsetting temperature to be 1100-1000 ℃.
8. The diesel valve manufacturing process according to claim 4, wherein after the electric upsetting is completed and before the die forging forming is performed, heat preservation treatment is performed to ensure that the forging starting temperature of the electric upsetting piece meets the die forging requirement.
9. The diesel valve manufacturing process according to claim 4, wherein the die used for die forging comprises an upper die and a lower die; the lower die is used for forming the outline dimension of the diesel engine air valve; the upper die is used for increasing the deformation of the central area of the electric upsetting garlic and promoting the central area of the electric upsetting garlic to be dynamically recrystallized; the upper die comprises a flat die, a male die and a female die; and selecting different types of upper dies or upper die combinations according to the external dimension of the diesel engine air valve to match with the lower die for die forging forming.
10. The process for manufacturing the diesel valve as claimed in claim 4, wherein the raw material is the electric upsetting rod material made of the high chromium nickel-based superalloy as claimed in claim 1.
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