CN111455306A - Manufacturing process of nickel-based tungsten carbide wear-resistant coating of metal hard sealing ball valve - Google Patents
Manufacturing process of nickel-based tungsten carbide wear-resistant coating of metal hard sealing ball valve Download PDFInfo
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- CN111455306A CN111455306A CN202010379623.XA CN202010379623A CN111455306A CN 111455306 A CN111455306 A CN 111455306A CN 202010379623 A CN202010379623 A CN 202010379623A CN 111455306 A CN111455306 A CN 111455306A
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- 238000000576 coating method Methods 0.000 title claims abstract description 101
- 239000011248 coating agent Substances 0.000 title claims abstract description 100
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 title claims abstract description 66
- 229910052759 nickel Inorganic materials 0.000 title claims abstract description 32
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 29
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 title claims abstract description 25
- 238000007789 sealing Methods 0.000 title claims abstract description 22
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 18
- 239000002184 metal Substances 0.000 title claims abstract description 18
- 239000000463 material Substances 0.000 claims abstract description 61
- 238000010438 heat treatment Methods 0.000 claims abstract description 37
- 239000000843 powder Substances 0.000 claims abstract description 37
- 238000000034 method Methods 0.000 claims abstract description 26
- 238000005507 spraying Methods 0.000 claims abstract description 24
- 238000000227 grinding Methods 0.000 claims abstract description 22
- 238000010285 flame spraying Methods 0.000 claims abstract description 14
- 238000004140 cleaning Methods 0.000 claims abstract description 11
- 238000007788 roughening Methods 0.000 claims abstract description 6
- 238000001816 cooling Methods 0.000 claims abstract description 4
- 239000007921 spray Substances 0.000 claims description 26
- 239000000956 alloy Substances 0.000 claims description 16
- 229910045601 alloy Inorganic materials 0.000 claims description 16
- 238000005488 sandblasting Methods 0.000 claims description 16
- 238000002844 melting Methods 0.000 claims description 13
- 230000008018 melting Effects 0.000 claims description 13
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 7
- 239000003350 kerosene Substances 0.000 claims description 7
- 239000001301 oxygen Substances 0.000 claims description 7
- 229910052760 oxygen Inorganic materials 0.000 claims description 7
- 239000000446 fuel Substances 0.000 claims description 6
- 229910003460 diamond Inorganic materials 0.000 claims description 4
- 239000010432 diamond Substances 0.000 claims description 4
- 239000007789 gas Substances 0.000 claims description 4
- 239000002245 particle Substances 0.000 claims description 4
- 238000004321 preservation Methods 0.000 claims description 4
- 239000012459 cleaning agent Substances 0.000 claims description 3
- 238000006073 displacement reaction Methods 0.000 claims description 3
- 238000005498 polishing Methods 0.000 claims description 3
- 239000002904 solvent Substances 0.000 claims description 3
- 239000004576 sand Substances 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- 238000000354 decomposition reaction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- QFXZANXYUCUTQH-UHFFFAOYSA-N ethynol Chemical group OC#C QFXZANXYUCUTQH-UHFFFAOYSA-N 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
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Abstract
The invention discloses a manufacturing process of a nickel-based tungsten carbide wear-resistant coating of a metal hard sealing ball valve, which comprises the following steps: s1, workpiece surface pretreatment: cleaning and roughening the surfaces of the machined ball body and the machined valve seat; s2, spraying the wear-resistant coating: uniformly spraying the wear-resistant coating powder material on the surfaces of the ball body and the valve seat by adopting a supersonic flame spraying process; s3, heating and remelting: putting the sprayed ball body and the valve seat into a vacuum furnace in batches for heating and remelting to enable the ball body and the valve seat to be metallurgically bonded with the wear-resistant material; s4, cooling: the ball body and the valve seat are slowly cooled along with the vacuum furnace after remelting; s5, grinding: and (4) precisely grinding the cooled ball body and the valve seat in sequence by adopting a grinding device. The invention can improve the strength of the wear-resistant coating of the sealing surface of the ball valve, further enhance the wear-resistant performance of the sealing surface of the ball valve and prolong the service life of the sealing surface of the ball valve.
Description
Technical Field
The invention relates to the technical field of wear-resistant coatings of valves, in particular to a manufacturing process of a nickel-based tungsten carbide wear-resistant coating of a metal hard sealing ball valve.
Background
The metal hard sealing ball valve is usually used for hard solid particle media, and the sealing surface of the ball valve is required to have good wear resistance, scratch resistance, high temperature resistance and corrosion resistance. In order to meet the above requirements, wear-resistant materials are usually sprayed on the surfaces of the ball body and the valve seat of the metal hard seal ball valve, and the following two processes are generally adopted: (1) oxy-acetylene flame spraying process; (2) supersonic flame spraying process. Both of these approaches have some disadvantages.
Problems encountered with the oxyacetylene flame spray process: A. although the nickel-based alloy wear-resistant coating is melted to the surface of the matrix through high-temperature heating and is metallurgically bonded with the matrix material, the bonding strength is high, but the wear-resistant coating is only melted to the surface of the matrix, and the compactness of the wear-resistant coating is low, so that the wear-resistant coating has poor wear resistance, and a sealing surface is easy to rub and damage under severe working conditions. B. Before the wear-resistant material is sprayed, flame is adopted to heat the ball body or the valve seat, the wear-resistant material powder can not be firmly attached to the surface of the ball body when the heating temperature is too low, the wear-resistant material can not be melted and combined with the base material of the ball body or the valve seat after remelting, and the wear-resistant material coating is easy to fall off when in use. The high flame heating temperature can easily cause the oxidation of the surface material of the sphere, and seriously affect the spraying quality. C. When the flame is used for heating and remelting the wear-resistant material, because the thickness difference of each part of the sphere is large, the uniform heating of each part of the sphere is difficult to ensure, the burning loss of certain elements in the nickel-based alloy can be caused by overhigh heating temperature, and the remelting and metallurgical bonding of the wear-resistant material and the matrix material can not be realized by overlow heating temperature. In addition, heating with a flame in the atmosphere also leads to oxidation of the material and a reduction in the quality of the coating. D. The flame heating needs a fast temperature rise speed, the temperature rise process is too slow, the material can be seriously oxidized at high temperature, but the temperature rise speed is too fast, the uniformity of the temperature of the ball body is not easy to ensure, and the material is easy to crack.
Problems encountered with supersonic flame spraying: A. the powder of the wear-resistant material is sprayed on the surface of the base material at a very high speed, so that the powder of the wear-resistant material and the base material have very high compactness, but the powder of the wear-resistant material is sprayed on the surface of the base material at a high speed by adopting supersonic flame spraying, the powder of the wear-resistant material is not melted together at a high temperature, the powder of the wear-resistant material and the base material are not metallurgically bonded, the bonding strength is low, and the powder of the wear-resistant material and. B. The supersonic flame spraying is adopted, the wear-resistant coating is sprayed on the surface of the substrate layer by layer in an overlapping manner, the thickness of the coating is small, and the binding force between the wear-resistant coating and the substrate is reduced by increasing the thickness of the coating, so that the wear-resistant coating sprayed by the supersonic flame is small in thickness and cannot completely meet the wear-resistant requirement of a harsh working condition.
Disclosure of Invention
The invention aims to provide a manufacturing process of a nickel-based tungsten carbide wear-resistant coating of a metal hard seal ball valve, which can improve the strength of the wear-resistant coating of a ball valve sealing surface, further enhance the wear resistance of the ball valve sealing surface and prolong the service life of the ball valve sealing surface.
In order to achieve the purpose, the invention provides the following technical scheme: a manufacturing process of a nickel-based tungsten carbide wear-resistant coating of a metal hard sealing ball valve comprises the following steps:
s1, workpiece surface pretreatment: cleaning and roughening the surfaces of the machined ball body and the machined valve seat;
s2, spraying the wear-resistant coating: uniformly spraying the wear-resistant coating powder material on the surfaces of the ball body and the valve seat by adopting a supersonic flame spraying process;
s3, heating and remelting: putting the sprayed ball body and the valve seat into a vacuum furnace in batches for heating and remelting to enable the ball body and the valve seat to be metallurgically bonded with the wear-resistant material;
s4, cooling: the ball body and the valve seat are slowly cooled along with the vacuum furnace after remelting;
s5, grinding: and (4) precisely grinding the cooled ball body and the valve seat in sequence by adopting a grinding device.
Preferably, the thickness of the wear-resistant coating in the step S2 is 0.3-1.0 mm, the wear-resistant coating is made of nickel-based alloy coated with tungsten carbide, and the grade of the nickel-based alloy is Ni60 or Ni 65.
Preferably, when the supersonic flame is used to spray the ball in step S2, the ball needs to be mounted on the rotating shaft to rotate at a constant speed, the manipulator controls the spray gun to perform reciprocating linear motion to spray the wear-resistant material powder on the surface of the ball, and the manipulator controls the displacement speed of the spray gun to gradually slow down from the two poles to the middle of the ball, so as to ensure that each part on the surface of the ball is uniformly sprayed.
Preferably, when the valve seat is sprayed by using the supersonic flame in step S2, the rotatable tool fixture is used to clamp the valve seat and drive the valve seat to rotate, and the spray gun is controlled to spray the abrasive powder onto the surface of the valve seat when the valve seat rotates.
Preferably, when the vacuum furnace is used for heating and remelting the ball or the valve seat in the step S3, the heating temperature of the ball or the valve seat is slowly and stably raised by the vacuum furnace, and the whole temperature rise time is controlled to be 4-8 hours according to the ball or the valve seat with different specifications; when the temperature in the vacuum furnace rises to be close to the melting point temperature of the wear-resistant coating material, a heat preservation process of 1.25-1.75 hours is needed to ensure that the temperature of each part on the whole sphere or valve seat is uniform, and then the temperature is raised to be the melting point temperature of the wear-resistant material and is kept for 6-10 minutes.
Preferably, the supersonic flame spraying process is that aviation kerosene is used as fuel, high-pressure oxygen is used as combustion-supporting gas, the fuel is combusted in a nozzle of a spray gun to generate high-temperature and high-pressure flame flow, and the wear-resistant coating powder is converted into molten or semi-molten particles in the flame flow and collides with the surface of a ball or a valve seat at high speed to form the wear-resistant coating.
Preferably, when the wear-resistant coating powder is sprayed in the step S2, the ratio of oxygen to aviation kerosene is 4.2-5.6, the flame speed is higher than Mach 7, the flame temperature is 2600-3200 ℃, the flight speed of the molten powder is higher than 720m/S, the powder feeding amount is 38-60g/min, and the spraying distance is 350-380 mm.
Preferably, the surface cleaning of the machined ball and valve seat in the step S1 includes oil stain and rust cleaning, the oil stain on the surface of the ball and valve seat is cleaned by a solvent cleaning agent, if the oil stain has penetrated into the ball or valve seat, the oil stain is burnt by flame, the rust layer on the surface of the ball and valve seat is subjected to acid leaching, then cleaning and drying, and then removed by mechanical polishing or sand blasting; the surfaces of the machined ball body and the machined valve seat are roughened by sand blasting, sand with the granularity of 16-60 # is adopted in the sand blasting process, the sand blasting pressure is 0.5-0.7 Mpa, and the roughness of the surfaces of the ball body and the valve seat after sand blasting is Ra 3-9.
Preferably, the grinding device in the step S5 is a diamond grinder, and the grinding amount of the wear-resistant coating on the surfaces of the ball and the valve seat is 6 to 10 μm.
The invention has the technical effects and advantages that:
1. the invention sprays the wear-resistant coating on the surfaces of the ball body and the valve seat and then carries out the heating remelting process by using the vacuum furnace, so that the ball body, the valve seat and the wear-resistant material on the surfaces of the ball body and the valve seat are metallurgically bonded, the bonding strength is high, and the compactness of the wear-resistant coating is higher, therefore, the wear-resistant coating has stronger wear resistance, and the sealing surface is not easy to rub and damage under severe working conditions. The ball body and the valve seat which are sprayed with the wear-resistant coating are heated and cooled by the vacuum furnace, the ball body and the valve seat can be prevented from being oxidized in the heating process to influence the spraying quality, the heating temperature is uniform, the burning loss and the melting and dripping of the wear-resistant material in the heating process are avoided, and the ball body and the valve seat are also effectively prevented from generating cracks, so compared with the traditional manufacturing process, the manufacturing process has better comprehensive performance.
2. The thickness of the wear-resistant coating is 0.3-1.0 mm, the wear-resistant coating is greatly thicker than that of the traditional wear-resistant coating, and the wear resistance of a sealing surface is obviously improved. The wear-resistant coating material is formed by coating tungsten carbide on the nickel-based alloy, the nickel-based alloy can be heated and remelted so as to be metallurgically combined with the ball body and the valve seat, the combination is firm, the wear resistance of the tungsten carbide is good, the problem of poor wear resistance of the nickel-based alloy is solved, the wear resistance of the wear-resistant coating is improved, the tungsten carbide is coated on the nickel-based alloy, and the burning loss of the tungsten carbide in the spraying and remelting processes is effectively avoided.
3. The invention can ensure the uniformity of the powder of the wear-resistant material sprayed on each part of the surface of the sphere by controlling the spray gun to spray the powder of the wear-resistant material on the surface of the sphere by using a manipulator while the sphere is arranged on the rotating shaft to rotate.
4. The valve seat is fixed by the rotatable tool clamp, and the spray gun is controlled to spray the grinding material powder on the surface of the valve seat when the valve seat rotates, so that the uniformity of spraying the wear-resistant material powder on each part of the surface of the valve seat can be ensured.
5. The heating temperature of the ball body or the valve seat is slowly and stably raised through the vacuum furnace, so that the whole ball body or the valve seat is slowly heated, the uniform heating of the ball body or the valve seat is ensured, the temperature of each part on the whole ball body or the valve seat can be ensured by the heat preservation process carried out when the temperature in the vacuum furnace is raised to be close to the melting point temperature of the wear-resistant material, then the temperature is raised to be the melting point temperature of the wear-resistant coating material and is kept for 6-10 minutes, the uniform heating of the whole ball body is ensured, the metallurgical bonding of the wear-resistant material and the ball body or the valve seat is also ensured, and meanwhile, the melting. The temperature can be accurately controlled by heating the vacuum furnace, the situation that the wear-resistant coating material is not metallurgically combined with the ball body and the valve seat due to too low temperature is prevented, and the burning loss of certain elements in the wear-resistant material due to too high temperature is prevented.
6. The invention adopts aviation kerosene as fuel and takes high-pressure oxygen as combustion-supporting gas to burn in the nozzle of the spray gun to generate high-temperature and high-pressure flame flow, and the wear-resistant coating powder can be better dissolved and is more uniformly distributed in the whole flame, thereby improving the covering efficiency and the coating quality.
7. The powder of the wear-resistant coating has high flying speed, large impact energy and high spraying efficiency, can form a high-quality wear-resistant coating which is compact and has high bonding strength and no layering phenomenon, and has low flame temperature and short stay heating time in flame in the spraying process, so that the phase change, oxidation and decomposition of the material are inhibited, and the spraying quality is improved.
8. The invention cleans the surface of the ball and the valve seat with oil stain and rust before the spraying process, and can ensure the bonding strength of the ball and the valve seat with the wear-resistant coating. The ball body and the valve seat after machining are subjected to surface roughening treatment, so that contact surfaces between the wear-resistant coating and the ball body and between the wear-resistant coating and the valve seat are increased, mechanical biting force between the wear-resistant coating and the ball body and between the wear-resistant coating and the valve seat is increased, the surface after purification treatment is activated, and the bonding strength between the ball body, the valve seat and the wear-resistant coating is improved. Meanwhile, the coarsening of the surfaces of the ball body and the valve seat also changes the distribution of residual stress in the wear-resistant coating, and is also favorable for improving the bonding strength of the wear-resistant coating.
9. The invention adopts a diamond grinder to precisely grind the cooled ball body and the valve seat in turn so as to meet the sealing requirement.
Drawings
FIG. 1 is a flow chart of a manufacturing process of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example (b): a manufacturing process of a nickel-based tungsten carbide wear-resistant coating of a metal hard sealing ball valve is shown in the attached figure 1, and comprises the following steps:
s1, workpiece surface pretreatment: cleaning and roughening the surfaces of the machined ball body and the machined valve seat;
s2, spraying the wear-resistant coating: uniformly spraying the wear-resistant coating powder material on the surfaces of the ball body and the valve seat by adopting a supersonic flame spraying process;
s3, heating and remelting: putting the sprayed ball body and the valve seat into a vacuum furnace in batches for heating and remelting to enable the ball body and the valve seat to be metallurgically bonded with the wear-resistant material;
s4, cooling: the ball and the valve seat are slowly cooled along with the vacuum furnace after remelting, so that the whole part is uniformly cooled and is not easy to generate defects such as cracks and the like;
s5, grinding: and (4) precisely grinding the cooled ball body and the valve seat in sequence by adopting a grinding device.
The ball body, the valve seat and the wear-resistant materials on the surfaces of the ball body and the valve seat are metallurgically bonded through the process, the bonding strength is high, and the compactness of the wear-resistant coating is high, so that the wear-resistant coating has high wear resistance, and the sealing surface is not easy to rub and damage under severe working conditions. The ball and the valve seat sprayed with the wear-resistant coating are heated and cooled by the vacuum furnace, so that the ball and the valve seat can be prevented from being oxidized in the heating process to influence the spraying quality, the heating temperature is uniform, the burning loss and the melting and dripping of the wear-resistant material in the heating process are avoided, and the ball and the valve seat are also effectively prevented from generating cracks, so that compared with the traditional manufacturing process, the manufacturing process has better comprehensive performance
The thickness of the wear-resistant coating in the step S2 is 0.3-1.0 mm, the wear-resistant coating is greatly thicker than that of a traditional wear-resistant coating, the wear-resistant performance of a sealing surface is remarkably improved, the wear-resistant coating is made of nickel-based alloy coated with tungsten carbide, the nickel-based alloy is selected from Ni60 or Ni65, and can be heated and remelted so as to be metallurgically combined with a ball body and a valve seat, the combination is firm, the wear-resistant performance of the tungsten carbide is good, the problem that the wear-resistant performance of the nickel-based alloy is poor is solved, the wear-resistant performance of the wear-resistant coating is improved, the nickel-based alloy is coated with the tungsten carbide, and the burning.
When the supersonic flame spraying is adopted for the spherical body in the step 2, the spherical body needs to be installed on the rotating shaft to rotate at a constant speed, the spray gun is controlled by the mechanical arm to do reciprocating linear motion to spray the wear-resistant material powder on the surface of the spherical body, and the displacement speed of the spray gun is controlled by the mechanical arm to gradually slow down from the two poles to the middle part of the spherical body, so that the uniform spraying of all parts on the surface of the spherical body can be ensured.
When the valve seat is sprayed by the supersonic flame in the step 2, the rotatable tool clamp is adopted to clamp the valve seat and drive the valve seat to rotate, and the spray gun is controlled to spray the grinding material powder on the surface of the valve seat when the valve seat rotates, so that the uniformity of the powder sprayed on each part of the surface of the valve seat can be ensured.
When the vacuum furnace is adopted to heat and remelt the ball or the valve seat in the step S3, the heating temperature of the ball or the valve seat is slowly and stably raised through the vacuum furnace, so that the heating uniformity of the ball or the valve seat is ensured, and the whole temperature rise time is controlled to be 4-8 hours according to the ball or the valve seat with different specifications; when the temperature in the vacuum furnace rises to be close to the melting point temperature of the wear-resistant coating material (generally, the temperature is about 40 ℃ lower than the melting point temperature, and for nickel-based alloy, the temperature is about 1000 ℃), a heat preservation process of 1.25-1.75 h is required to be carried out to ensure that the temperature of each part on the whole sphere or valve seat is uniform, then the temperature is raised to be the melting point temperature of the wear-resistant material (for nickel-based alloy, the temperature is 1040 ℃) and is kept for 6-10 minutes, so that the uniform heating of the whole sphere is ensured, the metallurgical bonding of the wear-resistant material and the sphere or valve seat is also ensured, and the melting loss of the wear-resistant. The temperature can be accurately controlled by heating the vacuum furnace, the situation that the wear-resistant coating material is not metallurgically combined with the ball body and the valve seat due to too low temperature is prevented, and the burning loss of certain elements in the wear-resistant material due to too high temperature is prevented.
The supersonic flame spraying process adopts aviation kerosene as fuel and high pressure oxygen as combustion-supporting gas to combust in a nozzle of a spray gun to generate high temperature and high pressure flame flow, and wear-resistant coating powder is converted into molten or semi-molten particles in the flame flow and impacts on the surface of a ball or a valve seat at high speed to form a wear-resistant coating.
Specifically, when the wear-resistant coating powder is sprayed in the step S2, the proportion of oxygen to aviation kerosene is 4.2-5.6, the flame speed is higher than Mach 7, the flame temperature is 2600-3200 ℃, the flight speed of the molten powder is higher than 720m/S, the powder feeding amount is 38-60g/min, and the spraying distance is 350-380 mm. The design of the parameters ensures that the powder of the wear-resistant coating has high flying speed, large impact energy and high spraying efficiency, can form a compact high-quality wear-resistant coating with high bonding strength and no layering phenomenon, and has low flame temperature and short stay heating time in flame in the spraying process, so that the phase change, oxidation and decomposition of the material are inhibited, and the spraying quality is improved.
The step S1 includes cleaning the surfaces of the machined ball and valve seat with oil and rust, the oil on the surfaces of the ball and valve seat is cleaned with solvent cleaning agent, if the oil has penetrated into the ball or valve seat, the oil is burnt off by flame, the rust on the surfaces of the ball and valve seat is acid-dipped, cleaned and dried, and then removed by mechanical polishing or sand blasting, the cleaning of the oil and rust can ensure the bonding strength of the ball and valve seat and the wear-resistant coating; the ball body and the valve seat after machining are subjected to surface roughening by sand blasting, so that contact surfaces between the wear-resistant coating and the ball body and between the wear-resistant coating and the valve seat are increased, mechanical engaging force between the wear-resistant coating and the ball body and between the wear-resistant coating and the valve seat is increased, the surface after purification treatment is activated, and the bonding strength between the ball body, the valve seat and the wear-resistant coating is improved. Meanwhile, the coarsening of the surfaces of the ball body and the valve seat also changes the distribution of residual stress in the wear-resistant coating, and is also favorable for improving the bonding strength of the wear-resistant coating. In the sand blasting process, 16-60 grit is adopted, the sand blasting pressure is 0.5-0.7 Mpa, and the roughness of the surfaces of the ball body and the valve seat after sand blasting is Ra 3-9. The ball and the valve seat after sand blasting are sprayed with wear-resistant coating materials within half an hour, so that the surfaces of the ball and the valve seat are prevented from being polluted and rusted due to overlong storage time.
In addition, the grinding device in the step S5 is a diamond grinder, and the grinding amount of the wear-resistant coating on the surfaces of the ball and the valve seat is 6-10 μm so as to meet the sealing requirement.
Claims (9)
1. A manufacturing process of a nickel-based tungsten carbide wear-resistant coating of a metal hard sealing ball valve is characterized by comprising the following steps: the method comprises the following steps:
s1, workpiece surface pretreatment: cleaning and roughening the surfaces of the machined ball body and the machined valve seat;
s2, spraying the wear-resistant coating: uniformly spraying the wear-resistant coating powder material on the surfaces of the ball body and the valve seat by adopting a supersonic flame spraying process;
s3, heating and remelting: putting the sprayed ball body and the valve seat into a vacuum furnace in batches for heating and remelting to enable the ball body and the valve seat to be metallurgically bonded with the wear-resistant material;
s4, cooling: the ball body and the valve seat are slowly cooled along with the vacuum furnace after remelting;
s5, grinding: and (4) precisely grinding the cooled ball body and the valve seat in sequence by adopting a grinding device.
2. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 1, wherein the manufacturing process comprises the following steps: in the step S2, the thickness of the wear-resistant coating is 0.3-1.0 mm, the wear-resistant coating is made of nickel-based alloy coated tungsten carbide, and the grade of the nickel-based alloy is Ni60 or Ni 65.
3. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 1, wherein the manufacturing process comprises the following steps: when the supersonic flame spraying is adopted in the step S2, the ball needs to be installed on the rotating shaft to rotate at a constant speed, the manipulator controls the spray gun to do reciprocating linear motion to spray the wear-resistant material powder on the surface of the ball, and the manipulator controls the displacement speed of the spray gun to gradually slow from the two poles to the middle part of the ball, so as to ensure that all parts on the surface of the ball are uniformly sprayed.
4. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 1, wherein the manufacturing process comprises the following steps: and when the valve seat is sprayed by adopting the supersonic flame in the step S2, clamping the valve seat by adopting a rotatable tool clamp and driving the valve seat to rotate, and controlling the spray gun to spray the grinding material powder on the surface of the valve seat when the valve seat rotates.
5. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 1, wherein the manufacturing process comprises the following steps: when the vacuum furnace is adopted to heat and remelt the ball or the valve seat in the step S3, the heating temperature of the ball or the valve seat is slowly and stably raised through the vacuum furnace, and the whole temperature rise time is controlled to be 4-8 hours according to the ball or the valve seat with different specifications; when the temperature in the vacuum furnace rises to be close to the melting point temperature of the wear-resistant coating material, a heat preservation process of 1.25-1.75 hours is needed to ensure that the temperature of each part on the whole sphere or valve seat is uniform, and then the temperature is raised to be the melting point temperature of the wear-resistant material and is kept for 6-10 minutes.
6. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 1, wherein the manufacturing process comprises the following steps: the supersonic flame spraying process is that aviation kerosene is used as fuel, high-pressure oxygen is used as combustion-supporting gas, the fuel burns in a nozzle of a spray gun to generate high-temperature and high-pressure flame flow, and wear-resistant coating powder is transformed into molten or semi-molten particles in the flame flow and impacts the surfaces of a ball body or a valve seat at high speed to form a wear-resistant coating.
7. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 6, wherein the manufacturing process comprises the following steps: when the wear-resistant coating powder is sprayed in the step S2, the proportion of oxygen to aviation kerosene is 4.2-5.6, the flame speed is higher than Mach 7, the flame temperature is 2600-3200 ℃, the flight speed of the molten powder is higher than 720m/S, the powder feeding amount is 38-60g/min, and the spraying distance is 350-380 mm.
8. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 1, wherein the manufacturing process comprises the following steps: the step S1 of cleaning the surfaces of the machined ball and valve seat includes oil stain and rust cleaning, the oil stain on the surfaces of the ball and valve seat is cleaned by solvent cleaning agent, if the oil stain has penetrated into the ball or valve seat, the oil stain is burnt by flame, the rust layers on the surfaces of the ball and valve seat are acid-dipped, cleaned and dried, and then removed by mechanical polishing or sand blasting; the surfaces of the machined ball body and the machined valve seat are roughened by sand blasting, sand with the granularity of 16-60 # is adopted in the sand blasting process, the sand blasting pressure is 0.5-0.7 Mpa, and the roughness of the surfaces of the ball body and the valve seat after sand blasting is Ra 3-9.
9. The manufacturing process of the nickel-based tungsten carbide wear-resistant coating of the metal hard seal ball valve according to claim 1, wherein the manufacturing process comprises the following steps: the grinding device in the step S5 is a diamond grinding machine, and the grinding amount of the wear-resistant coating on the surfaces of the ball and the valve seat is 6-10 mu m.
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| CN113755781A (en) * | 2021-09-08 | 2021-12-07 | 南京王行航空附件维修工程有限公司 | Method for repairing sealing surface of cylindrical shaft of high-pressure turbine clearance valve of airplane |
| CN113881913A (en) * | 2021-10-11 | 2022-01-04 | 浙江翰德圣智能再制造技术有限公司 | A kind of composite supersonic flame spraying high hardness wear-resistant coating technology method |
| CN114029702A (en) * | 2021-10-24 | 2022-02-11 | 洪泽东俊机械有限公司 | Manufacturing process of tungsten spraying valve plate |
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| CN114196903A (en) * | 2021-12-14 | 2022-03-18 | 江苏神通核能装备有限公司 | Wear-resistant valve spraying process |
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