CN108097928B - 一种表层复合材料的制备方法 - Google Patents
一种表层复合材料的制备方法 Download PDFInfo
- Publication number
- CN108097928B CN108097928B CN201711233117.4A CN201711233117A CN108097928B CN 108097928 B CN108097928 B CN 108097928B CN 201711233117 A CN201711233117 A CN 201711233117A CN 108097928 B CN108097928 B CN 108097928B
- Authority
- CN
- China
- Prior art keywords
- composite material
- prefabricated body
- ceramic particles
- ceramic
- powder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 53
- 239000002344 surface layer Substances 0.000 title claims abstract description 17
- 238000002360 preparation method Methods 0.000 title claims description 8
- 239000002245 particle Substances 0.000 claims abstract description 67
- 239000000919 ceramic Substances 0.000 claims abstract description 63
- 239000000463 material Substances 0.000 claims abstract description 24
- 229910052751 metal Inorganic materials 0.000 claims abstract description 21
- 239000002184 metal Substances 0.000 claims abstract description 21
- 238000000034 method Methods 0.000 claims abstract description 19
- 230000002787 reinforcement Effects 0.000 claims abstract description 19
- 239000010410 layer Substances 0.000 claims abstract description 17
- 230000007704 transition Effects 0.000 claims abstract description 13
- 238000005187 foaming Methods 0.000 claims abstract description 12
- 239000011159 matrix material Substances 0.000 claims abstract description 9
- 239000007788 liquid Substances 0.000 claims abstract description 6
- 238000010114 lost-foam casting Methods 0.000 claims abstract description 5
- 239000000843 powder Substances 0.000 claims description 15
- 239000011812 mixed powder Substances 0.000 claims description 10
- 239000003795 chemical substances by application Substances 0.000 claims description 9
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 7
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 7
- 229910001018 Cast iron Inorganic materials 0.000 claims description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 6
- 229910001208 Crucible steel Inorganic materials 0.000 claims description 4
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 claims description 4
- 230000009471 action Effects 0.000 claims description 4
- 239000012190 activator Substances 0.000 claims description 4
- 239000011230 binding agent Substances 0.000 claims description 4
- 239000011229 interlayer Substances 0.000 claims description 4
- 229920002401 polyacrylamide Polymers 0.000 claims description 4
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 3
- 229910000604 Ferrochrome Inorganic materials 0.000 claims description 3
- 239000010953 base metal Substances 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 230000003247 decreasing effect Effects 0.000 claims description 3
- 239000005011 phenolic resin Substances 0.000 claims description 3
- 229920001568 phenolic resin Polymers 0.000 claims description 3
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 2
- 229910001141 Ductile iron Inorganic materials 0.000 claims description 2
- 239000004698 Polyethylene Substances 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 claims description 2
- 229910045601 alloy Inorganic materials 0.000 claims description 2
- 239000000956 alloy Substances 0.000 claims description 2
- 235000013877 carbamide Nutrition 0.000 claims description 2
- 239000004202 carbamide Substances 0.000 claims description 2
- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 239000011651 chromium Substances 0.000 claims description 2
- -1 polyethylene Polymers 0.000 claims description 2
- 229920000573 polyethylene Polymers 0.000 claims description 2
- 229920002223 polystyrene Polymers 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims 2
- 229910052593 corundum Inorganic materials 0.000 claims 2
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 2
- 230000003213 activating effect Effects 0.000 claims 1
- 238000002156 mixing Methods 0.000 claims 1
- 238000003825 pressing Methods 0.000 claims 1
- 230000000694 effects Effects 0.000 abstract description 6
- 230000000977 initiatory effect Effects 0.000 abstract description 5
- 238000011161 development Methods 0.000 abstract description 4
- 239000000654 additive Substances 0.000 abstract 1
- 230000002708 enhancing effect Effects 0.000 abstract 1
- 229920006327 polystyrene foam Polymers 0.000 abstract 1
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 8
- 238000005266 casting Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 230000007423 decrease Effects 0.000 description 3
- 238000005065 mining Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 239000004566 building material Substances 0.000 description 2
- 239000004568 cement Substances 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
- 238000004663 powder metallurgy Methods 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910000677 High-carbon steel Inorganic materials 0.000 description 1
- 229910000617 Mangalloy Inorganic materials 0.000 description 1
- KCZFLPPCFOHPNI-UHFFFAOYSA-N alumane;iron Chemical compound [AlH3].[Fe] KCZFLPPCFOHPNI-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 239000012452 mother liquor Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
Images
Classifications
-
- 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
- B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/046—Use of patterns which are eliminated by the liquid metal in 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
- B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
- B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/063—Preparing or treating the raw materials individually or as batches
- C04B38/0635—Compounding ingredients
- C04B38/0645—Burnable, meltable, sublimable materials
- C04B38/067—Macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
- C04B2235/3232—Titanium oxides or titanates, e.g. rutile or anatase
- C04B2235/3237—Substoichiometric titanium oxides, e.g. Ti2O3
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3821—Boron carbides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Laminated Bodies (AREA)
Abstract
本发明涉及一种表层复合材料及其方法,属于新型材料的开发设计技术领域。本发明所述方法将陶瓷颗粒与添加剂制成具有成分梯度变化的圆柱状陶瓷预制体,通过EPS(聚苯乙烯泡沫)发泡将预制体嵌入模型当中,采用消失模铸造方法,制成表层复合材料。本发明通过对陶瓷颗粒增强体的结构设计,提高金属液在复合层中的填充效果,使陶瓷颗粒与基体具有结合良好的界面,利用过渡型界面的梯度效应,降低裂纹萌生扩张的倾向,产生具有良好致密性的复合层,达到增强复合材料性能的目的。
Description
技术领域
本发明公开了一种表层复合材料及其制备方法,属于新型材料的开发设计技术领域。
背景技术
在矿山、水泥、建材等工业领域存在大量的磨损工况,磨损失效是零部件的主要失效方式,耐磨材料的消耗是十分巨大的。以矿山行业为例,耐磨材料的消耗是仅次于电力消耗的第二大消耗成本构成部分。因此,在磨损工况下,如何提升耐磨材料的服役性能是实现节材降耗的重要研究课题。
材料的磨损是从材料的表面开始的,耐磨材料表面的抗磨性决定了其在磨损工况下的服役寿命,因此如何提升材料表面的抗磨性是耐磨材料开发和研究的重点。陶瓷颗粒增强表层复合材料结合了金属基体良好的塑韧性和支撑作用,以及高硬度陶瓷颗粒超高的耐磨性,是耐磨材料的重点研发方向。作为有着较高经济性的Al2O3陶瓷颗粒或者主要成分为Al2O3的陶瓷颗粒,有着极佳的服役性能和应用前景。但如何克服陶瓷颗粒与基体结合的弱界面效应,并消减复合层金属液填充不足造成的缺陷,以及陶瓷颗粒自身高脆性导致容易发生裂纹的萌生和扩展,是陶瓷颗粒增强表层复合材料设计和研发的重要命题。
专利CN 106584959A公开了一种高耐磨的铁铝层状复合材料及其制备方法,通过预制圆锥状增强体,逐渐减小增强体由表及里的体积分数,从而提高陶瓷颗粒预制体与母液金属的熔渗,再通过按层叠放,轧制,最终成型。该方法的预制体设计成分单一,预制体与基体之间的结合依然是无过渡的结合,并未改善陶瓷颗粒与金属液的浸润性问题。专利CN106367661A公开了一种颗粒增强铁基表面复合材料的制备方法,采用放点等离子烧结,预热浇铸以及热处理,制得陶瓷颗粒增强铁基复合材料。该方法对预处理的设备要求较高,制作工艺复杂,并且没有解决预制体与基体之间的过渡层性能优化的问题。专利CN106191496A公开了一种粉末冶金制备ZTA颗粒增强金属基耐磨复合材料的方法,利用活性金属元素粉末包覆ZTA颗粒表面,与金属基体混合后进行冷压成型,通过粉末冶金制得该材料。该方法通过添加活性金属元素粉末来改善界面问题,实际操作过于复杂,并且只能用于通过粉体成型。
发明内容
本发明的目的在于提供一种表层复合材料,该表层复合材料采用铸钢或铸铁作为基材,金属基材表面具有圆柱状陶瓷颗粒增强体,陶瓷颗粒增强体按照蜂窝结构进行排列;陶瓷颗粒增强体中陶瓷颗粒体积分数沿半径从圆心至圆柱面方向呈递减趋势。
本发明的另一目的在于提供一种表层复合材料的制备方法,该表层复合材料材料具有陶瓷颗粒与基体结合良好的界面,能够通过梯度结构的过渡界面抑制陶瓷颗粒裂纹的萌生扩展,其复合层有着良好的致密性;具体包括以下步骤:
(1)圆柱状陶瓷预制体的成型:将陶瓷颗粒、活化剂、粘结剂混合均匀得到混合粉末,再加入造孔剂;将几种陶瓷颗粒体积分数不同的混合粉末填装到分层模具中,陶瓷颗粒的体积分数沿圆心至圆柱面方向呈递减趋势;去除模具,将分层填装的松装预制体压制为陶瓷颗粒体积分数沿半径方向呈梯度变化的预制体。
(2)制备复合材料:将步骤(1)制备得到的预制体放入到EPS发泡模具底部,预制体按照蜂窝结构进行排列,然后进行EPS发泡,发泡后预制体被嵌入到EPS模型表面;采用消失模铸造方法浇注基体金属液,预制体在金属液作用下变为增强体,实现复合材料的成形得到表层复合材料。
优选的,本发明所述分层模具结构为多个圆柱形模具嵌套在一起组成的环状结构(如图6所示)。
优选的,本发明基体金属为高锰钢、合金钢、高铬钢、高碳钢、高铬铸铁、球墨铸铁中的任意一种。
优选的,本发明陶瓷颗粒为Al2O3颗粒或者主要成分为Al2O3的颗粒,颗粒粒度为20-80目。
优选的,本发明步骤(1)中造孔剂为聚乙烯、聚苯乙烯、聚乙烯醇、碳酰二胺的一中或几种,按照混合粉末总体积的5-30%进行添加;粘结剂为PVA(聚乙烯醇)、PAM(聚丙烯酰胺)或者酚醛树脂,总量按照混合粉末总质量的5-10%进行添加;活化剂为高碳铬铁粉末、Fe基自熔性合金粉末、SiC粉末、B4C粉末、Ti2O粉末中的一种或几种,按照混合粉末总质量的2-7%进行添加。
本发明可以通过改变分层模具和EPS发泡模具的几何尺寸,调整预制体的尺寸进而调整表层复合材料的结构参数,获得具有不同结构参数的复合材料,以适用与不同尺寸和不同使用工况的工件;其中,预制体的直径φ为5-30mm、预制体高度h为5-50mm、界面过渡区层数n为2-6、界面过渡区层间距d为1-5mm、预制体间距l为5-30mm。
本发明的有益效果:
(1)本发明通过对陶瓷颗粒增强体的结构设计,提出一种具有过渡界面和非连续复合层结构的表层复合材料,使陶瓷颗粒与基体之间具有结合良好的界面,解决Al2O3陶瓷颗粒或者主要成分为Al2O3的陶瓷颗粒与基体之间润湿性差,金属液在复合层中的填充效果不好,难以形成致密性好、性能优异的过渡层的问题,使得所制备的耐磨材料拥有更好的润湿性,能有效降低裂纹萌生扩张的倾向,产生具有良好致密性的复合层,达到提高复合材料性能的目的。
(2)本发明所述方法通过加入活化剂提升陶瓷颗粒与金属基体间的结合效果,设计非连续结构提升复合材料铸渗动力,提升金属液在复合层中的填充效果,利用具有梯度结构的过渡型界面提升降低裂纹萌生扩张的倾向,开发具有有效服役性能的陶瓷颗粒增强表层复合材料。
(3)本发明可以用于直接浇铸,在铸型内加入预制体即可实现产业化生产,并且通过蜂窝结构放置,能在保证复合材料性能的同时节约成本,得到更大的产业受益。本发明能有效发挥颗粒增强的优势,并且制造过程不需要复杂的机器设备,生产工艺简单,能快速实现量产化。该材料主要服役领域为矿山、水泥、建材等工业领域的磨损工况本。
附图说明
图1为本发明表层复合材料预制体俯视图;
图2为本发明表层复合材料预制体剖视图;
图3为本发明EPS模型结构剖视图;
图4为本发明EPS模型结构俯视图;
图5为本发明蜂窝结构单元;
图6为本发明分层填装模具结构示意图。
具体实施方式
为了更好的理解本发明,下面通过实施例对本发明进一步说明,实施例只用于解释本发明,不会对本发明构成任何的限定。
实施例1
一种高耐磨的复合材料衬板,该表层复合材料采用铸钢和铸铁作为基材,金属基材表面具有圆柱状陶瓷颗粒增强体,陶瓷颗粒增强体按照蜂窝结构进行排列;陶瓷颗粒增强体中陶瓷颗粒体积分数沿半径从圆心至圆柱面方向呈递减趋势(如图3~5所示)。
陶瓷颗粒增强体芯部半径r0为7mm,每一层厚度d为2mm;混合陶瓷颗粒和造孔剂的比例由外向芯的比例如表1所示。
表1 陶瓷颗粒和造孔剂的比例
本实施例所述复合材料衬板的制备方法,具体包括以下步骤:
(1)配置成分为90%Al2O3颗粒,5%PVA,5%高碳铬铁粉的混合陶瓷颗粒。
(2)将混合陶瓷颗粒与造孔剂按表1比例机械混合均匀,将陶瓷颗粒体积分数不同的混合陶瓷颗粒分层填装到分层模具中,填装结构如图6所示;去除模具,将分层填装的松装预制体按照一定的压力,压制为陶瓷颗粒体积分数沿半径方向呈梯度变化的预制体(如图1、2所示);(预制体的直径φ为30mm、预制体高度h为40mm、界面过渡区层数n为4、界面过渡区层间距d为5mm)。
(3)将预制体按图4所示摆放到EPS发泡模具中,预制体的间隔l为5mm;发泡后预制体被嵌入到EPS衬板模型中。
(4)利用消失模铸造方法对所得到的EPS衬板模型进行成型,预制体在金属液作用下变为增强体,实现复合材料的成形。
实施例2
一种高耐磨的复合材料衬板,该表层复合材料采用铸钢和铸铁作为基材,金属基材表面具有圆柱状陶瓷颗粒增强体,陶瓷颗粒增强体按照蜂窝结构进行排列;陶瓷颗粒增强体中陶瓷颗粒体积分数沿半径从圆心至圆柱面方向呈递减趋势。
陶瓷颗粒增强体芯部半径r0为10mm,每一层厚度d为2mm;陶瓷颗粒和造孔剂的比例由外向芯的比例如表2所示。
表2 陶瓷颗粒和造孔剂的比例
本实施例所述复合材料衬板的制备方法,具体包括以下步骤:
(1)配置成分为92%Al2O3颗粒,5%酚醛树脂,3%SiC粉末的混合陶瓷颗粒。
(2)将混合陶瓷颗粒与造孔剂按表2比例机械混合均匀,将陶瓷颗粒体积分数不同的混合陶瓷颗粒分层填装到分层模具中,填装结构如图6所示;去除模具,将分层填装的松装预制体按照一定的压力,压制为陶瓷颗粒体积分数沿半径方向呈梯度变化的预制体(如图1、2所示);(预制体的直径φ为10mm、预制体高度h为15mm、界面过渡区层数n为5、界面过渡区层间距d为5mm)。
(3)将预制体按图4所示摆放到EPS发泡模具中,预制体的间隔l为7mm;发泡后预制体被嵌入到EPS衬板模型中。
(4)利用消失模铸造方法对所得到的EPS衬板模型进行成型,预制体在金属液作用下变为增强体,实现复合材料的成形。
Claims (6)
1.一种表层复合材料的制备方法,其特征在于,具体包括以下步骤:
(1)圆柱状陶瓷预制体的成型:将陶瓷颗粒、活化剂、粘结剂混合均匀得到混合粉末,再加入造孔剂;将几种陶瓷颗粒体积分数不同的混合粉末填装到分层模具中,陶瓷颗粒的体积分数沿圆心至圆柱面方向呈递减趋势;去除模具,将分层填装的松装预制体压制为陶瓷颗粒体积分数沿半径方向呈梯度变化的预制体;
(2)制备复合材料:将步骤(1)制备得到的预制体放入到EPS发泡模具底部,预制体按照蜂窝结构进行排列,然后进行EPS发泡,发泡后预制体被嵌入到EPS模型表面;采用消失模铸造方法浇注基体金属液,预制体在金属液作用下变为增强体,实现复合材料的成形得到表层复合材料;
所述表层复合材料采用铸钢或铸铁作为基材,金属基材表面具有圆柱状陶瓷颗粒增强体,陶瓷颗粒增强体按照蜂窝结构进行排列;陶瓷颗粒增强体中陶瓷颗粒体积分数沿半径从圆心至圆柱面方向呈递减趋势。
2.根据权利要求1所述表层复合材料的制备方法,其特征在于:所述分层模具结构为多个圆柱形模具嵌套在一起组成的环状结构。
3.根据权利要求1所述表层复合材料的制备方法,其特征在于:基体金属为合金钢、高铬铸铁、球墨铸铁中的任意一种。
4.根据权利要求1所述表层复合材料的制备方法,其特征在于:陶瓷颗粒为Al2O3颗粒或者主要成分为Al2O3的颗粒,颗粒粒度为20-80目。
5.根据权利要求1所述表层复合材料的制备方法,其特征在于:步骤(1)中造孔剂为聚乙烯、聚苯乙烯、聚乙烯醇、碳酰二胺的一中或几种,按照混合粉末总体积的5-30%进行添加;粘结剂为PVA(聚乙烯醇)、PAM(聚丙烯酰胺)或者酚醛树脂,总量按照混合粉末总质量的5-10%进行添加;活化剂为高碳铬铁粉末、Fe基自熔性合金粉末、SiC粉末、B4C粉末、Ti2O粉末中的一种或几种,按照混合粉末总质量的2-7%进行添加。
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN201711233117.4A CN108097928B (zh) | 2017-11-30 | 2017-11-30 | 一种表层复合材料的制备方法 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN201711233117.4A CN108097928B (zh) | 2017-11-30 | 2017-11-30 | 一种表层复合材料的制备方法 |
Publications (2)
Publication Number | Publication Date |
---|---|
CN108097928A CN108097928A (zh) | 2018-06-01 |
CN108097928B true CN108097928B (zh) | 2020-08-25 |
Family
ID=62208817
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN201711233117.4A Active CN108097928B (zh) | 2017-11-30 | 2017-11-30 | 一种表层复合材料的制备方法 |
Country Status (1)
Country | Link |
---|---|
CN (1) | CN108097928B (zh) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN111136243B (zh) * | 2020-01-13 | 2021-06-18 | 中北大学 | 陶瓷/金属复合层的铸造方法 |
CN112874023B (zh) * | 2020-11-27 | 2024-11-12 | 南京航空航天大学 | 一种隔热保温及隔音降噪一体化材料及其制备方法 |
CN112589095A (zh) * | 2020-12-11 | 2021-04-02 | 西安交通大学 | 一种重力浸渗铁基复合材料预制体的高通量制备方法 |
CN115467228A (zh) * | 2022-09-22 | 2022-12-13 | 河北航科工程检测设备技术有限公司 | 一种免维护耐蚀支座及加工工艺 |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101775518A (zh) * | 2010-04-02 | 2010-07-14 | 哈尔滨工业大学 | 利用超声波制备颗粒增强梯度复合材料的装置及方法 |
CN103206589A (zh) * | 2013-03-23 | 2013-07-17 | 广州有色金属研究院 | 一种复合异形管道及其制造方法 |
CN103641487A (zh) * | 2013-12-02 | 2014-03-19 | 昆明理工大学 | 一种陶瓷预制体的制备方法及应用 |
CN106584959A (zh) * | 2016-10-24 | 2017-04-26 | 东莞市联洲知识产权运营管理有限公司 | 一种高耐磨的铁铝层状复合材料及其制备方法 |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
HUE039729T2 (hu) * | 2013-03-15 | 2019-01-28 | Rel Inc | Módosítható sûrûségû kompozit termékek és eljárás |
US20160138147A1 (en) * | 2013-06-19 | 2016-05-19 | European Space Agency | Method of manufacturing a metal matrix composite component by use of a reinforcement preform |
-
2017
- 2017-11-30 CN CN201711233117.4A patent/CN108097928B/zh active Active
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101775518A (zh) * | 2010-04-02 | 2010-07-14 | 哈尔滨工业大学 | 利用超声波制备颗粒增强梯度复合材料的装置及方法 |
CN103206589A (zh) * | 2013-03-23 | 2013-07-17 | 广州有色金属研究院 | 一种复合异形管道及其制造方法 |
CN103641487A (zh) * | 2013-12-02 | 2014-03-19 | 昆明理工大学 | 一种陶瓷预制体的制备方法及应用 |
CN106584959A (zh) * | 2016-10-24 | 2017-04-26 | 东莞市联洲知识产权运营管理有限公司 | 一种高耐磨的铁铝层状复合材料及其制备方法 |
Non-Patent Citations (1)
Title |
---|
锆刚玉/高铬铸铁基蜂窝陶瓷复合材料预制体优化;周谟金;《中国优秀硕士学位论文全文数据库》;20170215;第14-16页 * |
Also Published As
Publication number | Publication date |
---|---|
CN108097928A (zh) | 2018-06-01 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CN108097928B (zh) | 一种表层复合材料的制备方法 | |
CN103641487B (zh) | 一种陶瓷预制体的制备方法及应用 | |
CN102489686B (zh) | 消失模铸造陶瓷颗粒增强钢铁基复合材料的制备方法 | |
CN101899586B (zh) | 一种复合材料预制体的制备工艺 | |
CN103143699B (zh) | 金属-陶瓷预制件复合增强耐磨件及其制备方法 | |
CN106978561B (zh) | 一种呈柱状体搭接结构的预制体及利用该预制体制备局域化增强复合材料的方法 | |
CN106424740B (zh) | 一种碳化钨颗粒增强钢基表层复合材料及其制备方法 | |
CN104707972B (zh) | 一种复合耐磨件的制备方法 | |
CN106513107A (zh) | 一种复合挤压辊及其制备方法 | |
CN102513522A (zh) | 一种陶瓷颗粒增强钢铁基网状复合材料的制备方法 | |
CN113073248B (zh) | 一种wc预制体结构增强铁基复合材料及其制备方法 | |
CN103769563A (zh) | 一种活性元素烧结zta颗粒增强钢铁基复合磨辊及磨盘的制备方法 | |
CN104152777A (zh) | 一种TiC基钢结硬质合金复合耐磨增强体的制备方法 | |
CN111809100B (zh) | 一种NiCrAlY高温烧结ZTA颗粒增强钢铁基复合材料及其制备方法 | |
CN103331429B (zh) | 陶瓷金属复合预制体的制备方法 | |
CN103785841A (zh) | 一种浆料涂挂表面活化zta颗粒增强钢铁基复合耐磨件的制备方法 | |
CN101905185B (zh) | 一种破碎机用原位陶瓷局部增强复合材料锤头及制备方法 | |
CN101837444A (zh) | 一种高锰钢基SiC陶瓷颗粒复合材料的制备方法 | |
CN113718156B (zh) | 一种三维预制体结构wc颗粒增强铁基复合材料的制备方法 | |
CN104801695A (zh) | 一种常压铸渗法制备灰铸铁基表层耐磨复合材料的方法 | |
CN107150111A (zh) | 一种离心铸造制备耐磨挤压辊辊套的工艺方法 | |
CN111054903A (zh) | 一种具有空间网格状陶瓷金属复合层的耐磨件及其制备方法 | |
CN104741173B (zh) | 一种复合材料磨辊的制造方法 | |
CN106499755A (zh) | 柱状陶瓷增强轻金属复合材料制动盘 | |
CN105084927B (zh) | 一种蜂窝状陶瓷颗粒预制块的制备方法 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PB01 | Publication | ||
PB01 | Publication | ||
SE01 | Entry into force of request for substantive examination | ||
SE01 | Entry into force of request for substantive examination | ||
GR01 | Patent grant | ||
GR01 | Patent grant |