CN114871382B - Preparation method of micro-powder coated hexagonal prism ZTA/Fe composite material - Google Patents
Preparation method of micro-powder coated hexagonal prism ZTA/Fe composite material Download PDFInfo
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- CN114871382B CN114871382B CN202210461469.XA CN202210461469A CN114871382B CN 114871382 B CN114871382 B CN 114871382B CN 202210461469 A CN202210461469 A CN 202210461469A CN 114871382 B CN114871382 B CN 114871382B
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- 239000000843 powder Substances 0.000 title claims abstract description 78
- 239000002131 composite material Substances 0.000 title claims abstract description 69
- 238000002360 preparation method Methods 0.000 title claims abstract description 13
- 239000000919 ceramic Substances 0.000 claims abstract description 154
- 239000006260 foam Substances 0.000 claims abstract description 61
- 239000002245 particle Substances 0.000 claims abstract description 54
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 49
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 37
- 239000011651 chromium Substances 0.000 claims abstract description 37
- 229910052751 metal Inorganic materials 0.000 claims abstract description 36
- 239000002184 metal Substances 0.000 claims abstract description 36
- 229910001018 Cast iron Inorganic materials 0.000 claims abstract description 33
- 238000001035 drying Methods 0.000 claims abstract description 33
- 238000002156 mixing Methods 0.000 claims abstract description 30
- 239000011230 binding agent Substances 0.000 claims abstract description 28
- 238000000576 coating method Methods 0.000 claims abstract description 27
- 239000011248 coating agent Substances 0.000 claims abstract description 25
- 239000000203 mixture Substances 0.000 claims abstract description 25
- 239000000853 adhesive Substances 0.000 claims abstract description 22
- 230000001070 adhesive effect Effects 0.000 claims abstract description 22
- 238000000034 method Methods 0.000 claims abstract description 21
- 238000005266 casting Methods 0.000 claims abstract description 13
- 244000035744 Hura crepitans Species 0.000 claims abstract description 8
- 238000001816 cooling Methods 0.000 claims abstract description 8
- 238000005520 cutting process Methods 0.000 claims abstract description 8
- 239000003973 paint Substances 0.000 claims abstract description 7
- 238000005086 pumping Methods 0.000 claims abstract description 3
- 239000011159 matrix material Substances 0.000 claims description 23
- 239000010410 layer Substances 0.000 claims description 18
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 claims description 14
- 238000003756 stirring Methods 0.000 claims description 13
- 239000000126 substance Substances 0.000 claims description 9
- 230000007704 transition Effects 0.000 claims description 9
- 239000002344 surface layer Substances 0.000 claims description 8
- 229910003470 tongbaite Inorganic materials 0.000 claims description 7
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 6
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims description 2
- 239000004115 Sodium Silicate Substances 0.000 claims description 2
- 239000000835 fiber Substances 0.000 claims description 2
- 230000009970 fire resistant effect Effects 0.000 claims description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical group [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 6
- 238000005299 abrasion Methods 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 7
- 229910000831 Steel Inorganic materials 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 230000008569 process Effects 0.000 description 5
- 238000001514 detection method Methods 0.000 description 4
- 238000011049 filling Methods 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000008595 infiltration Effects 0.000 description 2
- 238000001764 infiltration Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000010114 lost-foam casting Methods 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 229910001000 nickel titanium Inorganic materials 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 230000007123 defense Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
- B22C7/023—Patterns made from expanded plastic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/06—Cast-iron alloys containing chromium
- C22C37/08—Cast-iron alloys containing chromium with nickel
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
Abstract
The invention discloses a preparation method of a micro powder coated hexagonal prism ZTA/Fe composite material, which belongs to the technical field of mechanical part casting and comprises the following process steps: cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model; mixing ceramic micropowder and binder uniformly; adding ZTA ceramic particles into the mixed material and uniformly mixing; putting the mixture of ceramic micro powder, adhesive and ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material preform lost foam model; bonding a layer of EPS pattern on the hexagonal prism honeycomb ZTA/Fe composite material preform lost foam model; and (3) coating refractory paint on the surface of the model, placing the model into a sand box, pumping negative pressure, pouring the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the hexagonal prism honeycomb ZTA/Fe composite material coated by the ceramic micro powder.
Description
Technical Field
The invention relates to the technical field of mechanical part casting, in particular to a preparation method of a micro powder coated hexagonal prism ZTA/Fe composite material.
Background
Fracture, corrosion and abrasion are three main failure modes of materials and equipment, and the inevitable abrasion phenomenon of the materials and the equipment in the service process causes serious consumable energy consumption. Wear-resistant metal materials are in great demand in a plurality of important industrial fields such as coal mines, metallurgy, electric power, buildings, national defense, traffic and the like, and a great part of the materials used for the metal wear-resistant parts in the industries are high-chromium cast iron. The working condition characteristics of the wear-resistant metal piece are mainly characterized by bearing complex stress and strong friction and impact, the service condition is very bad, and the serious use condition causes great material loss.
Aiming at different working conditions, scholars and enterprises at home and abroad have conducted a great deal of research on particle reinforced steel-based wear-resistant composite materials, SCHLENTHER E et Al prepare Al 2O3 particle reinforced 316L stainless steel-based composite materials by adopting a vacuum sintering method, and the result shows that the existence of Al 2O3 particles does not influence the corrosion resistance of the composite materials, and the corrosion resistance is mainly related to a steel matrix.
Some scholars uniformly mix ZTA ceramic particles with self-made binder to prepare ZTA ceramic preform, and the ZTA ceramic preform is compounded with molten metal by adopting a non-pressure casting infiltration method to obtain the ZTA ceramic particle reinforced steel-based composite material with the volume fraction of 47% -55%, and the wear resistance of the composite material is greatly improved compared with that of a metal matrix.
In the prior art, the ceramic prepared by ZTA is modified, then the modified ZTA ceramic particles are added into a die with a disc-shaped cavity, the die is removed after being pressed and formed, and the ceramic preform is prepared by heating and drying in a tube furnace protected by argon.
Mixing a plurality of metal powders, such as Fe-Cr-Ni-Ti micropowder coated ZTA to prepare a ceramic preform, wherein the technology comprises the steps of mixing pure Fe, cr, ni, ti simple substance powder with ZTA ceramic, placing the mixture into a mold, shaping and compacting the preform through a fastening mold, continuously introducing CO 2 gas for curing, and then drying and demolding to obtain the target product, namely the honeycomb ZTA ceramic preform coated with the Fe-Cr-Ni-Ti micropowder.
In the prior art, fe-Ti binders with different Ti contents are used for preparing porous ZTA ceramic particle preforms, the prepared preforms are placed in a lost foam, a composite material is obtained through the lost foam casting technology, and in the three-body abrasive wear detection of a sample, the wear resistance of the composite material containing 10wt% of Ti binder is 3 times that of high-chromium cast iron, and the wear resistance of the composite material containing 15wt% of Ti binder is 2.4 times that of high-chromium cast iron.
In summary, the ZTA ceramic has good toughness, and the ZTA ceramic particle reinforced steel-based composite material has good application prospect, but the ZTA ceramic particles and steel metal liquid have poor wettability and low bonding strength, and the composite material is easy to fall off particles in the abrasion process, has high production cost and is not suitable for mass production.
Disclosure of Invention
Aiming at the problems of complex process, low bonding strength of ZTA particles and a metal matrix, high production cost and complex process of the existing ZTA ceramic iron and steel material preform preparation technology, the invention aims to provide a preparation method of a micro powder coated hexagonal prism ZTA/Fe composite material.
In order to achieve the aim of the invention, the invention adopts the following technical scheme:
The preparation method of the micro powder coated hexagonal prism ZTA/Fe composite material comprises the following process steps:
a. cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. Mixing ceramic micropowder and binder uniformly;
c. Adding ZTA ceramic particles into the mixture of ceramic micro powder and binder, and uniformly mixing;
d. Putting the mixture of ceramic micro powder, binder and ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying to obtain a hexagonal prism-shaped honeycomb ZTA ceramic preform lost foam model;
e. Bonding a layer of EPS pattern on the hexagonal prism honeycomb lost foam model of the ZTA ceramic preform;
f. Coating fire-resistant paint on the surface of the hexagonal prism-shaped honeycomb vanishing mould with the EPS mould adhered on the surface layer and the ZTA ceramic preform inside, placing into a sand box, pumping negative pressure, pouring the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the hexagonal prism-shaped honeycomb ZTA/Fe composite material coated by ceramic micro powder.
The technical scheme of the invention is further improved as follows: the EPS foam board in the step a has the density of 22-25g/dm 3, and the shape and the size of the hexagonal prism honeycomb lost foam model can be adjusted according to the requirement of the part, for example, the side length of the hexagonal prism is 10.4mm.
The technical scheme of the invention is further improved as follows: in the step b, the addition of the ceramic micro powder accounts for 4-12% of the ZTA ceramic mass, the addition of the adhesive accounts for 8-15% of the ZTA mass, and the adhesive is a sodium silicate inorganic adhesive.
The technical scheme of the invention is further improved as follows: the ceramic micro powder in the step b is one or a mixture of Al2O3p、Al2O3f、TiC、Cr3C2、TiO2、TiNC、B4C、WC、SiC、Ni、Al、Co、Cr、NiCrBSi、MnO2, the particle size of the ceramic micro powder is 6.5-23 mu m, the fiber size of Al 2O3f is 10-20 mu m, and the length is 0.3-0.7mm.
The technical scheme of the invention is further improved as follows: in the step b, the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 200-350s in 120-200r/min, wherein in the step c, the mixing condition of ceramic micro powder and adhesive ZTA+ceramic particles is as follows: stirring for 200-350s in 120-200r/min, and fully ensuring that the surfaces of ZTA ceramic particles are uniformly coated with ceramic micro powder.
The technical scheme of the invention is further improved as follows: and d, drying the hexagonal prism honeycomb lost foam model at the temperature of 50-60 ℃ for 20-24 hours.
The technical scheme of the invention is further improved as follows: the coating process of the refractory coating in the step f is as follows: after the fireproof paint is coated, the paint is dried at the drying temperature of 50-60 ℃ and is repeated for three times, and the drying time is 7-8h each time.
The technical scheme of the invention is further improved as follows: the chemical components and the mass percentage content of the cast high-chromium cast iron are as follows: 2.8-3.2%, si:0.6-1.0%, mn:0.8-1.2%, cr:25-27%, mo:0.5-1.0%, ni:0.3-0.6%.
The technical scheme of the invention is further improved as follows: the casting process is carried out under the negative pressure of 0.03-0.06 MPa, and the casting temperature is 1470-1520 ℃.
By adopting the technical scheme, the invention has the following technical effects:
The EPS foam plate is adopted to cut and adhere the hexagonal prism honeycomb lost foam model, the preparation cost of the hexagonal prism honeycomb lost foam model is low, the hexagonal prism honeycomb lost foam model is not limited to hexagonal prism, the hexagonal prism honeycomb lost foam model can be suitable for the preparation of any complex shape, and the mixture of ceramic micro powder, adhesive and ZTA ceramic is not required to be taken out in the production process of the ZTA/Fe composite material, so that the production process is simple and convenient, and the production efficiency is improved.
In the preparation process of the ZTA/Fe composite material, hexagonal porous honeycomb holes are used, so that the contact area of the metal liquid and the ZTA ceramic preform is increased, the infiltration of the metal liquid to the ZTA ceramic preform is facilitated, and the bonding strength of the ZTA ceramic and the metal matrix and the wear resistance of the ZTA/Fe composite material casting are greatly improved due to the addition of ceramic micro powder.
The application uses high chromium cast iron as a metal matrix, ZTA ceramic particles as a reinforcement, selects proper ceramic micro powder to process the surfaces of the ZTA ceramic particles, prepares a ceramic preform with hexagonal prism honeycomb structure, prepares the ZTA ceramic particle reinforced high chromium cast iron based honeycomb structure composite material, and obtains a reactive interface. In order to solve the problems of low interface bonding strength and the like existing between ZTA ceramic particles and high-chromium cast iron melt and obtain a reactive interface, active ceramic micro powder such as Al2O3p、Al2O3f、TiC、Cr3C2、TiNC、B4C、WC、SiC、Ni、Al、Co、Cr、MnO2、NiCrBSi is added into a regular hexagonal honeycomb ZTA ceramic particle preform with the side length of 8.7mm and 10.4mm to prepare ZTA ceramic particle reinforced high-chromium cast iron test blocks with different active ceramic micro powder contents, and the influence of different ceramic particle types and addition amounts on the interface layer structure and the phase of the ZTA ceramic particle reinforced high-chromium cast iron composite material is researched by utilizing microscopic detection means such as SEM, EDS, XRD, so that a high-performance lost foam casting method which is suitable for mass production and is coated with micro powder is obtained.
Drawings
FIG. 1 is a schematic diagram of a lost foam pattern used for preparing a hexagonal honeycomb ZTA preform;
FIG. 2 is a cross-sectional view of FIG. 1;
FIG. 3 is a macroscopic structure chart of a test block without ceramic fine powder in example 1;
FIG. 4 is a microstructure of a test block without ceramic fine powder in example 1;
FIG. 5 is a macroscopic structure chart of a test block to which ceramic fine powder was added in example 2;
FIG. 6 is an EDS point scan of a composite block with ceramic micropowder addition of example 2;
FIG. 7 is a graph showing XRD detection results of a composite block containing ceramic fine powder according to example 2;
FIG. 8 is a graph showing the wear profile of a composite block to which ceramic fine powder was added in example 2.
Detailed Description
The technical scheme of the invention is described in detail below with reference to the specific embodiments.
Example 1
A. cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. uniformly mixing the adhesive and ZTA ceramic particles, wherein the addition amount of the adhesive accounts for 10% of the mass of ZTA; the mixing conditions of the binder and the ZTA ceramic particles are as follows: stirring for 300s in 150 r/min;
c. Putting the mixture of the adhesive and the ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying at 50 ℃ for 22 hours;
d. bonding a layer of EPS pattern on a hexagonal prism-shaped lost foam pattern containing a binder and ZTA ceramic mixture;
e. coating a fireproof coating on the surface of the hexagonal prism-shaped lost foam model with the EPS model adhered on the surface layer and the adhesive and ZTA ceramic mixture in the surface layer, drying at a drying temperature of 55 ℃ after the fireproof coating is coated, and repeating the steps for three times, wherein the drying time is 7h each time to obtain the hexagonal prism-shaped honeycomb-shaped lost foam model;
f. Putting the hexagonal prism honeycomb vanishing mould model containing the adhesive and ZTA ceramic mixture into a sand box, and combining with a pouring system to form a box;
g. And pouring high-chromium cast iron molten metal under negative pressure, pouring the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the hexagonal prism honeycomb ZTA/Fe composite material.
The chemical components and the mass percentage content of the cast high-chromium cast iron are as follows: 2.8-3.2%, si:0.6-1.0%, mn:0.8-1.2%, cr:25-27%, mo:0.5-1.0%, ni:0.3-0.6%. The negative pressure is 0.04MPa, and the casting temperature is 1480 ℃.
Samples were cut from the above composite materials, and the properties were measured and the metallographic structure thereof was observed. The experimental data, macroscopic and microscopic textures obtained were as follows:
Table 1 wear test parameters
Table 2 wear data for test blocks of ceramic micropowder-free composite
The macroscopic structure of example 1 is shown in fig. 3;
the microstructure of example 1 is shown in FIG. 4.
Example 2
A. Cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model, as shown in figure 1;
b. The ceramic micropowder type and the relative ZTA ceramic particle mass ratio thereof are as follows ：B4C：2％,Al2O3p：2％,Al2O3f：1.5％,TiO2：1％,Ni：1％,Al：0.5％,Cr：0.5％,NiCrBSi：0.5％;
C. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s in 180 r/min;
d. Adding ZTA ceramic particles into the mixture of ceramic micro powder and binder, and uniformly mixing under the following mixing conditions: stirring for 260s in 180 r/min;
e. Placing the mixture of the ceramic micro powder, the binder and the ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying at 55 ℃ for 24 hours to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material preform lost foam model;
f. Bonding a layer of EPS pattern on a hexagonal prism honeycomb lost foam pattern containing ceramic micro powder, a binder and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic preform);
g. Coating a fireproof coating on the surface of the hexagonal prism-shaped honeycomb-shaped lost foam model with the EPS model adhered on the surface layer and the ZTA ceramic preform inside, drying at a drying temperature of 55 ℃ after coating the fireproof coating, and repeating the steps for three times, wherein the drying time is 8 hours each time;
h. Putting the hexagonal prism honeycomb vanishing mould model containing the ZTA ceramic preform into a sand box, and combining with a pouring system to form a box;
i. And (3) pouring high-chromium cast iron molten metal under negative pressure, filling the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the micro-powder coated hexagonal honeycomb ZTA/Fe composite material.
The chemical components and the mass percentage content of the cast high-chromium cast iron are as follows: 2.8-3.2%, si:0.6-1.0%, mn:0.8-1.2%, cr:25-27%, mo:0.5-1.0%, ni:0.3-0.6%. The negative pressure is 0.04MPa, and the casting temperature is 1500 ℃.
Samples were cut from the composite material of example 2, and the properties were measured and their metallographic structure was observed. The experimental data, macroscopic and microscopic textures obtained were as follows:
table 3 example 1 and example 2 test block wear data
TABLE 4 example 2 test block EDS Point scan results
The macroscopic structure of example 2 is shown in fig. 5.
An EDS point scan of the composite block of example 2 is shown in fig. 6.
As shown in FIG. 7, XRD detection results of the composite block of example 2 show that FeB、Fe2B、Zr3NiO、Al74Cr20Si6、Fe0.88Ti1.11Zr0.94O5 and other new phases are found.
Example 3
A. cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. The ceramic micropowder type and the relative ZTA ceramic particle mass ratio are ：B4C：2.0％,Al2O3f：2.0％、Cr3C2：2.0％、TiNC：1.0％、MnO2：1.0％、SiC：0.5％、NiCrBSi：0.5％;
C. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s in 180 r/min;
d. Adding ZTA ceramic particles into the mixture of ceramic micro powder and binder, and uniformly mixing under the following mixing conditions: stirring for 260s in 180 r/min;
e. Placing the mixture of the ceramic micro powder, the binder and the ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying at 55 ℃ for 24 hours to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material preform lost foam model;
f. Bonding a layer of EPS pattern on a hexagonal prism honeycomb lost foam pattern containing ceramic micro powder, a binder and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic preform);
g. Coating a fireproof coating on the surface of the hexagonal prism-shaped honeycomb-shaped lost foam model with the EPS model adhered on the surface layer and the ZTA ceramic preform inside, drying at a drying temperature of 55 ℃ after coating the fireproof coating, and repeating the steps for three times, wherein the drying time is 8 hours each time;
h. Putting the hexagonal prism honeycomb vanishing mould model containing the ZTA ceramic preform into a sand box, and combining with a pouring system to form a box;
i. And (3) pouring high-chromium cast iron molten metal under negative pressure, filling the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the micro-powder coated hexagonal honeycomb ZTA/Fe composite material.
The chemical components and the mass percentage content of the cast high-chromium cast iron are as follows: 2.8-3.2%, si:0.6-1.0%, mn:0.8-1.2%, cr:25-27%, mo:0.5-1.0%, ni:0.3-0.6%. The negative pressure is 0.04MPa, and the casting temperature is 1500 ℃.
Samples were cut from the composite materials and measured for performance. The experimental data obtained are as follows:
TABLE 5 wear resistance data of ceramic micropowder coated ZTA/Fe composite test blocks
Example 4
A. and cutting and bonding the EPS foam plate to obtain the hexagonal prism-shaped lost foam model.
B. the ceramic micropowder type and the relative ZTA ceramic particle mass ratio are ：Al2O3p：2.0％、Al2O3f：2.0％、Cr3C2：2.0％、TiNC：1.0％、Co：1.0％、Cr：1.0％、MnO2：0.5％、WC：0.5％;
C. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s in 180 r/min;
d. Adding ZTA ceramic particles into the mixture of ceramic micro powder and binder, and uniformly mixing under the following mixing conditions: stirring for 260s in 180 r/min;
e. Placing the mixture of the ceramic micro powder, the binder and the ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying at 55 ℃ for 24 hours to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material preform lost foam model;
f. Bonding a layer of EPS pattern on a hexagonal prism honeycomb lost foam pattern containing ceramic micro powder, a binder and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic preform);
g. Coating a fireproof coating on the surface of the hexagonal prism-shaped honeycomb-shaped lost foam model with the EPS model adhered on the surface layer and the ZTA ceramic preform inside, drying at a drying temperature of 55 ℃ after coating the fireproof coating, and repeating the steps for three times, wherein the drying time is 8 hours each time;
h. Putting the hexagonal prism honeycomb vanishing mould model containing the ZTA ceramic preform into a sand box, and combining with a pouring system to form a box;
i. And (3) pouring high-chromium cast iron molten metal under negative pressure, filling the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the micro-powder coated hexagonal honeycomb ZTA/Fe composite material.
The chemical components and the mass percentage content of the cast high-chromium cast iron are as follows: 2.8-3.2%, si:0.6-1.0%, mn:0.8-1.2%, cr:25-27%, mo:0.5-1.0%, ni:0.3-0.6%. The negative pressure is 0.04MPa, and the casting temperature is 1500 ℃.
Table 6 ceramic micropowder coated ZTA/Fe composite test block wear resistance data
Example 5
A. cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. the ceramic micropowder type and the relative ZTA ceramic particle mass ratio are ：Al2O3p：2.0％、Al2O3f：2.0％、TiNC：1.5％、Cr3C2：1.0％、MnO2：1.0％、Co：0.5％、NiCrBSi：0.5％、Ni：0.5％、B4C：0.5％;
C. Uniformly mixing the ceramic micro powder and the adhesive, wherein the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 260s in 180 r/min;
d. Adding ZTA ceramic particles into the mixture of ceramic micro powder and binder, and uniformly mixing under the following mixing conditions: stirring for 260s in 180 r/min;
e. Placing the mixture of the ceramic micro powder, the binder and the ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying at 55 ℃ for 24 hours to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material preform lost foam model; ;
f. Bonding a layer of EPS pattern on a hexagonal prism honeycomb lost foam pattern containing ceramic micro powder, a binder and a ZTA ceramic mixture (hereinafter referred to as ZTA ceramic preform);
g. Coating a fireproof coating on the surface of the hexagonal prism-shaped honeycomb-shaped lost foam model with the EPS model adhered on the surface layer and the ZTA ceramic preform inside, drying at a drying temperature of 55 ℃ after coating the fireproof coating, and repeating the steps for three times, wherein the drying time is 8 hours each time;
h. Putting the hexagonal prism honeycomb vanishing mould model containing the ZTA ceramic preform into a sand box, and combining with a pouring system to form a box;
i. And (3) pouring high-chromium cast iron molten metal under negative pressure, filling the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the micro-powder coated hexagonal honeycomb ZTA/Fe composite material.
The chemical components and the mass percentage content of the cast high-chromium cast iron are as follows: 2.8-3.2%, si:0.6-1.0%, mn:0.8-1.2%, cr:25-27%, mo:0.5-1.0%, ni:0.3-0.6%. The negative pressure is 0.04MPa, and the casting temperature is 1500 ℃.
Samples were cut from the composite materials and measured for performance. The experimental data obtained are as follows:
TABLE 7 wear resistance data of ceramic micropowder coated ZTA/Fe composite test block
In the above examples 2-5, the wear resistance of the ZTA/Fe composite material was greatly improved, which indicates that after the active micro powder coated with the ZTA ceramic particles, the transition layer between the metal matrix and the ceramic particles has an element diffusion behavior, and the elements in the active micro powder chemically react with both the metal matrix and the ceramic particles at a high temperature, so it can be determined that the transition layer has different degrees of reactive wetting with the metal matrix and the ceramic particles, i.e., metallurgical bonding exists between the transition layer and the metal matrix and the ceramic particles.
After the high-chromium cast iron samples are ground and polished, each sample randomly finds a flat and smooth part, and 9 points are distributed at equal intervals, and the Vickers hardness is recorded; the composite material sample is obtained by taking 3 points at equal distance at three parts of the metal matrix, the ceramic particles and the transition layer, taking 3 groups, respectively recording the hardness, and then taking an average value.
TABLE 6 average microhardness of ZTA/Fe composite material
The hardness of the transition layer of the composite material added with the active micro powder is obviously improved compared with that of the intermediate layer without the active micro powder.
The abrasion performance of example 1 is 3.76 times higher than that of the high-chromium cast iron matrix sample, which shows that the abrasion performance of ZTA/Fe composite material is obviously enhanced after ZTA ceramic particles are added in the high-chromium cast iron metal matrix, the abrasion performance of example 2, example 3, example 4 and example 5 is higher than that of the high-chromium cast iron matrix sample, the bonding property between the ceramic particles without coating active micro powder and the metal matrix is poor through analyzing the abrasion mechanism, and the hard and brittle carbide peeling phenomenon is found to be serious in the matrix with relatively long distance from the ceramic particles. The reason for this phenomenon may be that the metal matrix surrounding the ceramic particles forms more hard and brittle carbides under the action of the ceramic particles "micro-chill", and after the metal matrix is gradually worn out, the carbides fall off, so that the bearing effect of the metal matrix on the ceramic particles is reduced, cracks are generated between the metal matrix and the ceramic particles under the action of wear, and the ceramic particles tend to fall off from the matrix. After the micro powder is added, the abrasion appearance of the sample is mainly micro cutting scratch and furrow, and the phenomenon of peeling is not easy to occur due to the increase of the bonding strength of ZTA and a matrix, in addition, the transition layer between ZTA particles and a metal matrix has abrasion-resistant phase, and the hardness of the transition layer is also increased, so that the mass loss caused by abrasive particle abrasion is effectively reduced, and the abrasion resistance of the composite material is improved.
Example 6
The shape and the size of the honeycomb ZTA/Fe composite material preform lost foam model are examined, the adopted ZTA ceramic particles, ceramic micro powder components and the proportion, the chemical components of cast high-chromium cast iron, the mass percent and the test steps are the same as those of the embodiment 2, the difference is that the shape and the size of the honeycomb ZTA/Fe composite material preform lost foam model are the same, the micro powder coated hexagonal prism honeycomb ZTA/Fe composite material is prepared by using the prefabricated lost foam models with different shapes and sizes, and the abrasion resistance and the hardness are tested, and the concrete table is as follows:
from the results, the honeycomb ZTA/Fe composite preform lost foam model is a hexagonal prism, and the abrasion resistance is best and the hardness value of the transition layer is highest when the side length of the hexagonal prism is 10.4 mm.
Claims (8)
1. The preparation method of the micro powder coated hexagonal prism ZTA/Fe composite material comprises the following process steps:
a. cutting and bonding the EPS foam plate to obtain a hexagonal prism-shaped lost foam model;
b. Mixing ceramic micropowder and binder uniformly; the ceramic micro powder is mixed by B 4C、Al2O3p、Al2O3f、TiO2 and Ni, al, cr, niCrBSi or mixed by B 4C、Al2O3f、Cr3C2、TiNC、MnO2, siC and NiCrBSi or Al2O3p、Al2O3f、TiNC、Cr3C2、MnO2、Co、NiCrBSi、Ni、B4C; the grain diameter of the ceramic micro powder is 6.5-23 mu m, the fiber size of Al 2O3f is 10-20 mu m, the length is 0.3-0.7mm, and the adding amount of the ceramic micro powder accounts for 4-12% of the quality of ZTA ceramic;
c. Adding ZTA ceramic particles into the mixture of ceramic micro powder and binder, and uniformly mixing;
d. Putting the mixture of ceramic micro powder, adhesive and ZTA ceramic into a prepared hexagonal prism-shaped lost foam model, and drying to obtain a hexagonal prism-shaped honeycomb ZTA/Fe composite material preform lost foam model;
e. bonding a layer of EPS pattern on the hexagonal prism honeycomb ZTA/Fe composite material preform lost foam model;
f. Coating fire-resistant paint on the surface of the hexagonal prism-shaped honeycomb vanishing mould with the EPS mould adhered on the surface layer and the ZTA ceramic preform inside, placing the hexagonal prism-shaped honeycomb vanishing mould into a sand box, pumping negative pressure, pouring the poured high-chromium cast iron molten metal along a pouring system, and cooling to obtain the hexagonal prism-shaped honeycomb ZTA/Fe composite material coated by ceramic micro powder, wherein a wear-resistant phase is generated on a transition layer between ZTA particles of the ZTA/Fe composite material and a metal matrix, and the hardness is increased.
2. The method for preparing the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 1, wherein the method comprises the following steps: the EPS foam board in step a has a density of 22-25g/dm 3.
3. The method for preparing the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 1, wherein the method comprises the following steps: in the step b, the addition amount of the binder accounts for 8-15% of the ZTA mass, and the binder is sodium silicate inorganic binder.
4. The method for preparing the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 1, wherein the method comprises the following steps: in the step b, the mixing conditions of the ceramic micro powder and the adhesive are as follows: stirring for 200-350s in 120-200r/min, wherein the mixing conditions of ceramic micro powder, binder and ZTA ceramic particles in the step c are as follows: stirring for 200-350s in 120-200 r/min.
5. The method for preparing the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 1, wherein the method comprises the following steps: and d, drying the hexagonal prism honeycomb lost foam model, wherein the drying temperature is 50-60 ℃ and the drying time is 20-24 h.
6. The method for preparing the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 1, wherein the method comprises the following steps: the coating process of the refractory coating in the step f is as follows: after the fireproof paint is coated, the paint is dried at the drying temperature of 50-60 ℃ and is repeated for three times, and the drying time is 7-8h each time.
7. The application of the preparation method of the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 1, which is characterized in that: the chemical components and the mass percentage content of the cast high-chromium cast iron are as follows: 2.8-3.2%, si:0.6-1.0%, mn:0.8-1.2%, cr:25-27%, mo:0.5-1.0%, ni:0.3-0.6%.
8. The application of the preparation method of the micro powder coated hexagonal prism shaped ZTA/Fe composite material according to claim 7, which is characterized in that: the casting process is carried out under the negative pressure of 0.03-0.06 MPa, and the casting temperature is 1470-1520 ℃.
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