阅读说明：本技术 金属基体收缩率可控的耐磨块及其制备装置和方法及应用 (Wear-resistant block with controllable metal matrix shrinkage rate and preparation device, method and application thereof ) 是由 佟伟平 高菁 李铁帅 于 2021-08-31 设计创作，主要内容包括：一种金属基体收缩率可控的耐磨块及其制备装置和方法及应用,属于耐磨设备领域。该金属基体收缩率可控的耐磨块的制法为：根据其原料,准备物料混合；将混合物料装入坩埚内,将混合物料压实,然后将填满物料的坩埚,采用中频感应加热至1200～1500℃,进行加热并对物料进行下压,物料下压的深度根据金属基体理论收缩率计算,采用程序控制液压装置的下压深度来间接控制金属基体收缩率。该金属基体收缩率可控的耐磨块用于耐磨辊套或板锤,具有优异的耐磨性能。采用该种耐磨块的制备方法生产效率高,金属基体收缩率可通过液压装置的下压深度来间接控制,节能环保。(A wear-resistant block with a controllable metal matrix shrinkage rate, a preparation device and a method thereof and application belong to the field of wear-resistant equipment. The preparation method of the wear-resistant block with the controllable shrinkage rate of the metal matrix comprises the following steps: preparing materials for mixing according to raw materials; the mixed material is filled into a crucible, the mixed material is compacted, then the crucible filled with the material is heated to 1200-1500 ℃ by adopting medium-frequency induction heating, the material is heated and pressed down, the pressing depth of the material is calculated according to the theoretical shrinkage rate of the metal matrix, and the pressing depth of a hydraulic device is controlled by a program to indirectly control the shrinkage rate of the metal matrix. The wear-resistant block with the controllable metal matrix shrinkage rate is used for a wear-resistant roller sleeve or a plate hammer and has excellent wear resistance. The preparation method of the wear-resistant block has high production efficiency, the shrinkage rate of the metal matrix can be indirectly controlled through the pressing depth of the hydraulic device, and the preparation method is energy-saving and environment-friendly.)

1. The utility model provides a preparation facilities of controllable wear-resisting piece of metal matrix shrinkage factor, its characterized in that, this preparation facilities of controllable wear-resisting piece of metal matrix shrinkage factor is intermediate frequency induction heating machine, including insulating support, at the inside induction coil that is provided with of insulating support, be provided with the circulating water cooling chamber between induction coil and insulating support, be provided with the crucible inside the cavity that the induction coil formed, be provided with the crucible furnace lining between crucible and the induction coil, above the cavity that insulating support formed, be provided with hydraulic means, the hydraulic means below is provided with the pressure head, the pressure head bottom is provided with the preforming, induction coil and converter connect.

2. The device for preparing the wear-resistant block with the controllable metal matrix shrinkage rate according to claim 1, wherein the output voltage of a frequency converter is 380V, and the current frequency is 150-8000 Hz.

3. The device for preparing the wear-resistant block with the controllable metal matrix shrinkage rate according to claim 1, wherein the hydraulic device is an automatic press and is used for controlling the descending depth of a pressure head and automatically retracting to a specified height after reaching a target depth; the pressure head and the pressing sheet are both made of alumina ceramic materials, and the pressing sheet is a replaceable consumable material; the crucible is one of an alumina crucible or a zirconia crucible; the shape of the crucible is determined according to the shape of the wear-resistant block with controllable shrinkage rate of the metal matrix to be prepared; the crucible furnace lining is made of refractory materials, in particular to a heat preservation felt silicon dioxide heat preservation and insulation material; the cooling medium of the circulating water cooling cavity is water, the water inlet temperature is 15-30 ℃, and the water outlet temperature is controlled to be less than 50 ℃.

4. A preparation method of a wear-resistant block with a controllable metal matrix shrinkage rate is characterized by comprising the following steps:

step 1: preparation of

Preparing materials according to raw materials of the prepared wear-resistant block with the controllable metal matrix shrinkage; uniformly mixing the raw materials to obtain a mixed material;

the wear-resistant block with the controllable shrinkage rate of the metal matrix comprises ceramic reinforced particles and high-chromium cast iron alloy powder, wherein the ceramic reinforced particles are prepared from the following raw materials in percentage by volume: high-chromium cast iron alloy powder 1: (2-3); the ceramic reinforced particles are used as a reinforced phase, and the high-chromium cast iron alloy powder is used as a metal matrix;

step 2: filling

Putting the mixed material into a crucible, wherein the height of the mixed material is 1/2-4/5 of the total height of the crucible, compacting the mixed material, and filling ceramic reinforcing particles into the residual space in the crucible to obtain a crucible filled with the material;

and step 3: heating of

Heating the crucible filled with the material to 1200-1500 ℃ by adopting medium-frequency induction heating, pressing down the material, correcting the pressing-down depth of the material according to the theoretical shrinkage rate of the metal matrix, and calculating to obtain the crucible filled with the material, wherein the specific calculation method comprises the following steps:

when the crucible is cylindrical, the calculation formula is as follows:

when the crucible is in a circular truncated cone shape, the calculation formula is as follows:

wherein h is the depth of depression, V_mIs the apparent volume of the metal powder, S is the bottom area inside the crucible, R₁Is the radius of the bottom in the crucible, and theta is the included angle between the side wall of the cylindrical crucible and the horizontal plane;

and pressing to obtain the wear-resistant block with the controllable shrinkage rate of the metal matrix.

5. The method for preparing the wear-resistant block with the controllable metal matrix shrinkage rate according to claim 4, wherein in the step 1, the high-chromium cast iron alloy powder comprises the following chemical components in percentage by mass: c: 2.0-4.0%, Si: 0.1-1.2%, Mn: 0.1-15%, Cr: 10-30%, Mo: 0-6%, W: 0-10, Ni: 0-4.0%, Cu: 0 to 1.0%, and the balance of Fe and inevitable impurities.

6. The method of claim 4, wherein the ceramic reinforcing particles are oxide ceramic particles and/or carbide ceramic particles, specifically ZTA (ZrO) ceramic particles₂-Al₂O₃) Granules, ZTA (30% ZrO)₂-Al₂O₃) One or a mixture of more of balls, WC particles and SiC particles.

7. The method for preparing a wear-resistant block with a controllable metal matrix shrinkage rate according to claim 4, wherein in the step 3, the pressing rate is 0.5-2 mm/s, and the pressing is maintained for 10-60 s after the pressing is carried out to the calculated pressing depth.

8. The wear-resistant block with the controllable shrinkage rate of the metal matrix is characterized in that the wear-resistant block is prepared by the preparation method of any one of claims 1 to 7, the reinforcing phase is uniformly distributed in the metal matrix, the wear resistance of the wear-resistant block is according to American ASTM-G65 standard and JBT7705-1995 standard, and the weight loss of the wear-resistant block is 0.0492-0.0614G when the wear-resistant block is formed into 1400m by adopting an MLG-130 wear machine test; the shrinkage rate of the metal matrix of the wear-resistant block with the controllable shrinkage rate of the metal matrix is 20-45%.

9. The use of the abrasion-resistant block with the controllable metal matrix shrinkage rate of claim 8, wherein the abrasion-resistant block with the controllable metal matrix shrinkage rate is used for an abrasion-resistant roller sleeve or a plate hammer;

the method comprises the following steps of carrying out heat treatment on the wear-resistant block with the controllable shrinkage rate of the metal matrix and the wear-resistant part using the wear-resistant block together, wherein the heat treatment comprises the following steps:

the method comprises the following steps: quenching the wear-resistant block with the controllable metal matrix shrinkage rate to obtain a quenched wear-resistant block;

step two: and tempering the quenched wear-resistant block to obtain the final wear-resistant block with the controllable metal matrix shrinkage rate.

10. The application of the wear-resistant block with the controllable metal matrix shrinkage rate according to claim 9 is characterized in that in the first step, the quenching temperature is 950-1050 ℃, the heating rate is 8-9 ℃/min, the heat preservation time is 2-3 h, and air cooling is performed after quenching;

in the second step, the tempering temperature is 400-600 ℃, the heating rate is 8-9 ℃/min, the heat preservation time is 2-4 h, and furnace cooling is adopted after tempering.

Technical Field

The invention belongs to the field of wear-resistant equipment, and particularly relates to a wear-resistant block with a controllable metal matrix shrinkage rate, and a preparation device, a preparation method and application thereof.

Background

The metal ceramic composite material is known as a wear-resistant material in the 21 st century, and has the advantages of metal plasticity, metal toughness, high strength and ceramic rigidity and the like. The vertical mill is an ideal large-scale grinding device and is widely applied to the industries of cement, electric power, metallurgy, chemical industry, non-metal ore and the like. It integrates crushing, drying, grinding and grading conveying into a whole, has high production efficiency, and can grind blocky, granular and powdery raw materials into required powdery materials. The roller sleeve is a core component of a vertical mill, and mainly comprises three types of high-chromium cast iron wear-resistant roller sleeves, wear-resistant steel overlaying roller sleeves and metal-based ceramic composite material wear-resistant roller sleeves in domestic markets. The market share of the first two traditional roller sleeves is about 80%. The market share of the metal-based ceramic composite material wear-resistant roller sleeve is about 20%, and the market share is improved year by year due to the excellent wear resistance and high cost performance.

The Chinese patent publication (publication) No. CN108342657A discloses a high-wear-resistance metal ceramic composite roll sleeve, which comprises a preset inner sleeve and an outer sleeve, wherein the preset inner sleeve is made of common medium-low carbon steel or low alloy steel, and the outer sleeve is cast by a high-wear-resistance alloy and metal ceramic composite material reinforced block. Wherein, the preparation process of the metal ceramic composite material reinforced block adopts a program temperature control liquid phase sintering method, which has large energy consumption and low production efficiency. More importantly, the shrinkage rate of the metal matrix is uncontrollable by adopting a liquid phase sintering method. The sintered body contains a large amount of millimeter-scale large particles, and the shrinkage caused by the solidification of the liquid phase of the sintered body is difficult to reach the high compactness of a metal matrix, so that the comprehensive mechanical property of the wear-resistant block is seriously influenced. Therefore, external force is required to control the shrinkage rate of the reinforcing block during sintering.

Disclosure of Invention

Aiming at the problems in the prior art, the invention provides a wear-resistant block with a controllable metal matrix shrinkage rate, a preparation device and a method thereof, and an application thereof. The metal ceramic composite wear-resistant block can be used for preparing a vertical grinding rod sleeve. The preparation technology adopts an intermediate frequency induction heating machine which is independently researched and developed, and the intermediate frequency induction heating machine has the advantages of high melting speed, high production efficiency, strong adaptability, flexible use, convenient starting operation, energy conservation, environmental protection and the like. The medium-frequency induction heating machine has reasonable structure and function design, simple and flexible process preparation, and can indirectly control the shrinkage rate of the metal matrix by calculating and adopting a program to control the pressing depth of the hydraulic device. The prepared metal wear-resistant block adopts a hydraulic method, applies external force, increases the density of a sintered body, can realize controllable shrinkage rate of a matrix, improves the comprehensive mechanical property of the wear-resistant block, and has excellent wear resistance. The preparation method of the wear-resistant block has high production efficiency, the shrinkage rate of the metal matrix can be indirectly controlled through the pressing depth of the hydraulic device, the energy consumption is low, and the preparation method conforms to the national energy-saving and environment-friendly concept.

The invention relates to a preparation device of a wear-resistant block with a controllable metal matrix shrinkage rate, which is a medium-frequency induction heating machine and comprises an insulating support, wherein an induction coil is arranged in the insulating support, a circulating water cooling cavity is arranged between the induction coil and the insulating support, a crucible is arranged in a cavity formed by the induction coil, a crucible furnace lining is arranged between the crucible and the induction coil, a hydraulic device is arranged above the cavity formed by the insulating support, a pressure head is arranged below the hydraulic device, a pressing sheet is arranged at the bottom of the pressure head, and the induction coil is connected with a frequency converter.

Preferably, the output voltage of the frequency converter is 380V, and the current frequency is 150-8000 Hz.

Furthermore, the hydraulic device is a press machine, can control the descending depth of the press head, and automatically retracts to the designated height after reaching the target depth.

Furthermore, the pressure head and the pressing sheet are both made of alumina ceramic materials, and the pressing sheet is a replaceable consumable material.

The crucible is preferably one of an alumina crucible or a zirconia crucible. The shape of the crucible is determined according to the shape of the wear-resistant block with controllable shrinkage rate of the metal matrix to be prepared, and the crucible is preferably a cylindrical crucible or a truncated cone crucible.

The crucible furnace lining is made of refractory materials, in particular to a heat preservation felt silicon dioxide heat preservation and insulation material.

The cooling medium of the circulating water cooling cavity is preferably water, the water inlet temperature is 15-30 ℃, and the water outlet temperature is controlled to be less than 50 ℃.

The invention relates to a preparation method of a wear-resistant block with a controllable metal matrix shrinkage rate, which comprises the following steps:

step 1: preparation of

Preparing materials according to raw materials of the prepared wear-resistant block with the controllable metal matrix shrinkage; uniformly mixing the raw materials to obtain a mixed material;

the wear-resistant block with the controllable shrinkage rate of the metal matrix comprises ceramic reinforced particles and high-chromium cast iron alloy powder, wherein the ceramic reinforced particles are prepared from the following raw materials in percentage by volume: high-chromium cast iron alloy powder 1: (2-3); the ceramic reinforced particles are used as a reinforced phase, and the high-chromium cast iron alloy powder is used as a metal matrix;

step 2: filling

Putting the mixed material into a crucible, wherein the height of the mixed material is 1/2-4/5 of the total height of the crucible, compacting the mixed material, and filling ceramic reinforcing particles into the residual space in the crucible to obtain a crucible filled with the material;

and step 3: heating of

Heating the crucible filled with the material to 1200-1500 ℃ by adopting medium-frequency induction heating, pressing down the material, correcting the pressing-down depth of the material according to the theoretical shrinkage rate of the metal matrix, and calculating to obtain the crucible filled with the material, wherein the specific calculation method comprises the following steps:

when the crucible is cylindrical, the calculation formula is as follows:

when the crucible is in the shape of a truncated cone, the calculation formula is：

Wherein h is the depth of depression, V_mIs the apparent volume of the metal powder, S is the bottom area inside the crucible, R₁Is the radius of the bottom in the crucible, and theta is the included angle between the side wall of the cylindrical crucible and the horizontal plane;

pressing to obtain the wear-resistant block with the controllable shrinkage rate of the metal matrix;

in the step 1, the high-chromium cast iron alloy powder comprises the following chemical components in percentage by mass: c: 2.0-4.0%, Si: 0.1-1.2%, Mn: 0.1-15%, Cr: 10-30%, Mo: 0-6%, W: 0-10, Ni: 0-4.0%, Cu: 0 to 1.0%, and the balance of Fe and inevitable impurities.

The ceramic reinforcing particles are oxide ceramic particles and/or carbide ceramic particles, specifically ZTA (ZrO)₂-Al₂O₃) Granules, ZTA (30% ZrO)₂-Al₂O₃) One or more of ball, WC particles and SiC particles are mixed, preferably ZTA (ZrO)₂-Al₂O₃) Particles with the granularity of 1000-1700 mu m; the ZTA (30% ZrO)₂-Al₂O₃) The preferred particle size of the spheres is 1 to 5 mm.

In the step 3, the pressing rate is preferably 0.5-2 mm/s, and the pressing is maintained for 10-60 s after the calculated pressing depth is reached.

The wear-resistant block with the controllable metal matrix shrinkage rate is prepared by the preparation method, the reinforcing phase is uniformly distributed in the metal matrix, the wear resistance of the wear-resistant block is according to the American ASTM-G65 standard and JBT7705-1995 standard, when the wear resistance of the wear-resistant block is 1400m through an MLG-130 wear machine test, the weight loss of the wear-resistant block is 0.0492-0.0614G, and the wear-resistant block has good wear resistance.

The shrinkage rate of the metal matrix of the wear-resistant block with the controllable shrinkage rate of the metal matrix is 20-45%.

The shape of the wear-resistant block with the controllable metal matrix shrinkage rate is preferably a cylinder or a circular truncated cone.

The wear-resistant block with the controllable metal matrix shrinkage rate is applied to a wear-resistant roller sleeve or a plate hammer, and is more preferably a vertical mill roller sleeve.

The method comprises the following steps of carrying out heat treatment on the wear-resistant block with the controllable shrinkage rate of the metal matrix and the wear-resistant part using the wear-resistant block together, wherein the heat treatment comprises the following steps:

the method comprises the following steps: quenching the wear-resistant block with the controllable metal matrix shrinkage rate to obtain a quenched wear-resistant block;

step two: and tempering the quenched wear-resistant block to obtain the final wear-resistant block with the controllable metal matrix shrinkage rate.

In the first step, the quenching temperature is 950-1050 ℃, the heating rate is 8-9 ℃/min, the heat preservation time is 2-3 h, and preferably air cooling is performed after quenching.

In the second step, the tempering temperature is 400-600 ℃, the heating rate is 8-9 ℃/min, the heat preservation time is 2-4 h, and furnace cooling is adopted after tempering.

The wear-resistant block with the controllable metal matrix shrinkage rate and the wear-resistant part using the wear-resistant block are subjected to heat treatment together, namely, the wear-resistant roller sleeve or the plate hammer prepared by later-stage casting after the heat treatment process of the wear-resistant block with the controllable metal matrix shrinkage rate is subjected to synchronous heat treatment.

Compared with the prior art, the wear-resistant block with the controllable metal matrix shrinkage rate, the preparation device and the method thereof and the application have the following advantages:

(1) the method is simple to operate, high in production efficiency and applicable to industrial production;

(2) the medium-frequency induction heating machine used in the invention has the advantages of high heating temperature, high speed, short heating time, uniform heating of the metal ceramic material, energy conservation, and accordance with the national energy-saving and environment-friendly concept, and the medium-frequency induction heating machine is provided with a pressure head to realize controllable shrinkage rate of the metal matrix;

(3) the wear-resistant block with the large-particle oxide metal matrix and the controllable shrinkage rate realizes metallurgical bonding between the oxide ceramic and the high-chromium cast iron matrix, and the high-chromium cast iron matrix has no obvious defects;

(4) the invention uses large-volume-fraction cheap large-particle oxide ceramics, so that the product cost is greatly reduced;

(5) the shrinkage rate of the large-particle oxide metal matrix prepared by the invention is controllable, and the oxide ceramic particles are uniformly distributed in the high-chromium cast iron matrix and the volume fraction is controllable;

(6) the wear-resistant block with the controllable shrinkage rate of the large-particle oxide metal matrix is prepared by an independently developed medium-frequency induction heating machine, and has a good wear-resistant effect.

(7) According to the invention, the shrinkage rate of the metal matrix is controlled by the wear-resistant block, so that the defects of pores and the like in the matrix can be reduced, the comprehensive mechanical property of the metal matrix is further enhanced, the service life of the metal matrix is further prolonged, and the economic value is reflected.

Drawings

FIG. 1 is a schematic view of an intermediate frequency induction heating machine according to the present invention;

in the figure, 1 is a hydraulic device, 2 is a pressure head, 3 is a pressing sheet, 4 is a crucible, 5 is a furnace lining, 6 is an induction coil, 7 is a circulating water cooling cavity, 8 is a water inlet, 9 is an insulating support, and 10 is a water outlet; a is high-chromium cast iron alloy liquid, and b is a ceramic ball;

FIG. 2 is a schematic structural view of a ZTA sphere-reinforced wear-resistant block with controllable shrinkage rate of a metal matrix in example 1 of the invention;

(a) the structural schematic diagram of the wear-resistant block with the controllable shrinkage rate of the metal matrix enhanced by the frustum-shaped ZTA ball is shown;

(b) the structure of the wear-resistant block is a schematic diagram of the cylindrical ZTA ball reinforced metal matrix shrinkage controllable wear-resistant block;

FIG. 3 is a schematic structural view of a ZTA particle-reinforced shrinkage-controllable wear-resistant block of embodiment 2 of the present invention;

(a) the structural diagram of the wear-resistant block with the controllable shrinkage rate of the metal matrix enhanced by the frustum-shaped ZTA particles is shown;

(b) the structure of the wear-resistant block is a schematic diagram of the cylindrical ZTA particle reinforced metal matrix shrinkage controllable wear-resistant block;

FIG. 4 is a schematic structural view of a wear-resistant block with controllable shrinkage rate of a ZTA sphere and ZTA particle mixed reinforced metal matrix in example 5 of the present invention;

(a) the structure of the wear-resistant block is a structural schematic diagram of a frustum-shaped ZTA ball and ZTA particle mixed reinforced metal matrix with controllable shrinkage rate;

(b) the structure of the wear-resistant block is a cylindrical ZTA ball and ZTA particle mixed reinforced metal matrix with controllable shrinkage;

FIG. 5 is a scanning electron microscope picture of the bonding interface of the ceramic reinforcing particles and the high-chromium cast iron matrix in the wear-resistant block with controllable metal matrix shrinkage according to example 1 of the present invention;

FIG. 6 is a photomicrograph of a cross section of a wear-resistant block with controllable shrinkage of a metal matrix in example 1 of the invention;

FIG. 7 is a photomicrograph of a cross section of a wear-resistant block with controllable shrinkage of a metal matrix in example 2 of the invention;

FIG. 8 is a process flow diagram of the method for preparing the wear-resistant block with the controllable shrinkage rate of the metal matrix.

Detailed Description

The present invention will be described in further detail with reference to examples.

In the following examples, the press is a table top servo press.

Example 1

The wear-resistant block with the controllable shrinkage rate of the metal matrix is a wear-resistant block with the controllable shrinkage rate of a large-particle oxide metal matrix, is a wear-resistant material and can be used for a metal ceramic vertical mill roller sleeve;

the controllable wear-resisting piece's of metal matrix shrinkage factor preparation facilities that this embodiment adopted, for intermediate frequency induction heating machine, its structural schematic shows fig. 1, including insulating support 9, at the inside induction coil 6 that is provided with of insulating support 9, the circulating water cooling chamber 7 that sets up between induction coil 6 and insulating support 9, circulating water cooling chamber 7 is provided with water inlet 8 and delivery port 10, coolant is the circulating water, crucible 4 at the inside setting of cavity that induction coil 6 formed, be provided with crucible furnace lining 5 between crucible 4 and the induction coil 6, cavity top at insulating support 9 formation is provided with hydraulic means 1, hydraulic means 1 below is provided with pressure head 2, pressure head 2 bottom is provided with preforming 3, induction coil 6 and converter connect.

The temperature interval of the medium-frequency induction heater is 1200 ℃. The output voltage of the frequency converter is 380V, and the current frequency is 150-8000 HZ.

The hydraulic device 1 can be automatically retracted to a designated height after being pressed down to a certain depth. The pressure head 2 and the pressing sheet 3 are made of alumina ceramic materials, and the pressing sheet 3 is a replaceable consumable material.

The crucible can adopt an alumina crucible or a zirconia crucible, and the embodiment is the alumina crucible.

The crucible shape include cylindrical crucible and round platform shape crucible, two kinds of shapes have been adopted in this embodiment.

The crucible furnace lining is made of refractory materials.

The induction coil and the water cooling system are cooled by circulating water, the water temperature at a water inlet is 15-30 ℃, and the water temperature at a water outlet is less than 50 ℃.

The preparation device of the wear-resistant block with the controllable metal matrix shrinkage rate is adopted to prepare the wear-resistant block with the controllable metal matrix shrinkage rate, the process flow block diagram of the preparation method is shown in figure 8, and the specific steps are as follows:

step 1, preparing a wear-resistant block raw material with a controllable metal matrix shrinkage rate:

preparing a metal matrix and a reinforcing phase; the metal matrix is high-chromium cast iron alloy powder, and the high-chromium cast iron alloy powder comprises the following chemical components in percentage by mass: c: 4.0%, Si: 1.2%, Mn: 2%, Cr: 10% and the balance of Fe and inevitable impurities; the reinforcing phase is ceramic reinforcing particles;

ceramic reinforcing particles in volume ratio: high-chromium cast iron alloy powder 1: 2; the ceramic reinforcing particles used in this example were oxide ceramic particles: in particular to ZTA ball (containing 30 percent of ZrO by mass percent)₂ZrO of₂-Al₂O₃) The particle size is 3-5 mm.

(1) And (5) cleaning the ZTA ball to obtain the cleaned ZTA ball.

(2) Weighing various powders for forming the high-chromium cast iron alloy powder according to the mixture ratio: high-carbon ferrochrome powder, ferromolybdenum powder, manganese powder and carbon powder are simultaneously filled into an industrial V-shaped powder mixer and mixed for 2 hours to obtain uniformly mixed high-chromium cast iron alloy powder;

(3) weighing the cleaned ZTA balls and the mixed high-chromium cast iron alloy powder in the step (2) according to the pre-calculated volume fraction of the ceramic reinforced particles, filling the balls and the mixed high-chromium cast iron alloy powder into a powder mixer, and fully mixing for 1h to obtain a mixed material;

step 2: filling

(1) Putting the mixed materials into a crucible, enabling the materials to account for four fifths of the total height of the crucible, and compacting the mixed materials in the crucible by using a steel column;

(2) filling the residual space of the crucible with ZTA balls to obtain a crucible filled with materials;

and step 3: heating of

(1) Loading the crucible filled with the materials into a medium-frequency induction heating machine, correcting errors of empirical parameters according to the calculated theoretical shrinkage rate of the high-chromium cast iron matrix, and setting the pressing depth of a control hydraulic device;

the cylindrical calculation method comprises the following steps:the calculation method of the truncated cone shape comprises the following steps:

wherein h is the depth of depression, V_mIs the apparent volume of the metal powder, S is the bottom area inside the crucible, R₁Is the radius of the bottom in the crucible, and theta is the included angle between the side wall of the cylindrical crucible and the horizontal plane;

after calculation, the depth of depression in this example is 18.35 mm.

(2) Starting the medium-frequency induction heater, setting a program according to the pressing depth, and allowing circulating water to enter from the water inlet (lower part) and gradually rise until the whole cavity is filled up and then be discharged from the water outlet (upper part). Circulating water is operated in the whole process line to ensure that the cavity is filled with water, and the heating procedure is carried out after the circulating water is circulated at a certain speed. After the heating temperature is reached, the pressing head of the hydraulic device is pressed down to reach a preset pressing depth, and then the hydraulic device automatically returns to an initial position; the heating temperature was 1200 ℃ and the pressing rate was 1.2mm/s, and the pressing was maintained for 40s after the calculated pressing depth.

(3) Taking out the crucible, and preparing the ZTA ball-reinforced wear-resistant block with the controllable shrinkage rate of the metal matrix;

the structure schematic diagram of the ZTA ball-reinforced metal matrix shrinkage-controllable wear-resistant block of the present embodiment is shown in fig. 2, where fig. 2(a) is a truncated cone shape, and fig. 2(b) is a cylinder shape.

The shrinkage of the metal matrix of the wear-resistant block with the controllable metal matrix shrinkage prepared by the process can be measured by a drainage method, the shrinkage of the matrix is 40%, the matrix hardness of the reinforced block is 55HRC, the composite material has no cracks, and the ceramic reinforced particles and the wear-resistant block matrix are metallurgically bonded (figure 5). The macroscopic photograph of the cross section of the obtained wear-resistant block with the controllable shrinkage rate of the metal matrix is shown in fig. 6, and fig. 6 illustrates that the reinforcing blocks are uniformly distributed. According to the American ASTM-G65 standard and JBT7705-1995 standard, when the wear resistance is 1400m by adopting an MLG-130 wear machine test, the weight loss is 0.0501G, and the wear resistance is good.

The wear-resistant block with the controllable shrinkage rate of the metal matrix reinforced by the ZTA ball prepared in the embodiment is used in a metal ceramic wear-resistant roller sleeve and is subjected to heat treatment together with the wear-resistant roller sleeve: the heat treatment process comprises the following steps:

quenching: quenching the cooled wear-resistant block with the controllable metal matrix shrinkage rate, wherein the specific process comprises the following steps:

quenching temperature: 1020 deg.C

The heating rate is as follows: 8 ℃/min

And (3) heat preservation time: 2h

A cooling mode: air cooling

Annealing: the air-cooled abrasion-resistant block with controllable metal matrix shrinkage is tempered by the specific process,

tempering temperature: 400 deg.C

The heating rate is as follows: 8 ℃/min

And (3) heat preservation time: 4h

A cooling mode: furnace cooling

And obtaining the final metal ceramic wear-resistant roller sleeve.

Example 2

A wear-resistant block with a controllable metal matrix shrinkage rate, which adopts the same preparation device as that of the embodiment 1.

The preparation method of the wear-resistant block with the controllable metal matrix shrinkage rate in the embodiment specifically comprises the following steps:

step 1, preparing a wear-resistant block raw material with a controllable metal matrix shrinkage rate:

preparing a metal matrix and a reinforcing phase; the metal matrix is high-chromium cast iron alloy powder, and the high-chromium cast iron alloy powder comprises the following chemical components in percentage by mass: c: 2.0%, Si: 0.1%, Mn: 2%, Cr: 30%, Mo: 0%, and the balance of Fe and inevitable impurities; the reinforcing phase is ceramic reinforcing particles;

ceramic reinforcing particles in volume ratio: high-chromium cast iron alloy powder 1: 3; the ceramic reinforcing particles used in this example were oxide ceramic particles: ZTA granule, 10 mesh.

(1) And (3) washing a large amount of water, then ultrasonically oscillating with alcohol, washing ZTA particles, and finally drying to obtain the cleaned ZTA particles.

(2) Weighing various powders for forming the high-chromium cast iron alloy powder according to the mixture ratio: high-carbon ferrochrome powder, ferromolybdenum powder, manganese powder and carbon powder are simultaneously filled into an industrial V-shaped powder mixer and mixed for 2 hours to obtain uniformly mixed high-chromium cast iron alloy powder;

the maximum loading volume of the V-shaped powder mixer used in this example was 20 liters each time, the maximum loading weight was 20 kg, and the rotational speed of the cylinder was 9 r/min.

(3) Weighing the cleaned ZTA particles and the mixed high-chromium cast iron alloy powder in the step (2) according to the pre-calculated volume fraction of the ceramic reinforced particles, filling the ZTA particles and the mixed high-chromium cast iron alloy powder into a powder mixer, and fully mixing for 1h to obtain a mixed material;

step 2: filling

(1) Putting the mixed materials into a crucible, enabling the materials to account for three fifths of the total height of the crucible, and compacting the mixed materials in the crucible by using a steel column;

(2) filling ZTA particles in the residual space of the crucible to obtain a crucible filled with materials;

and step 3: heating of

(1) Loading the crucible filled with the materials into a medium-frequency induction heating machine, correcting errors of empirical parameters according to the calculated theoretical shrinkage rate of the high-chromium cast iron matrix, and setting the pressing depth of a control hydraulic device;

the cylindrical calculation method comprises the following steps:the calculation method of the truncated cone shape comprises the following steps:

wherein h is the depth of depression, V_mIs the apparent volume of the metal powder, S is the bottom area inside the crucible, R₁Is the radius of the bottom in the crucible, and theta is the included angle between the side wall of the cylindrical crucible and the horizontal plane;

after calculation, the depth of depression in this example is 15.48 mm.

(2) The medium-frequency induction heater automatically returns to an initial position after a pressure head of the hydraulic device reaches a preset pressing depth according to a set program; the temperature interval of the medium frequency induction heater is 1500 ℃. The pressing rate was 1mm/s and was maintained for 30s after pressing to the calculated pressing depth.

(3) Circulating water enters from the water inlet (lower part) and gradually rises until the whole cavity is filled, and then is discharged from the water outlet (upper part). Circulating water is operated in the whole process line to ensure that the cavity is filled with water, and the heating procedure is carried out after the circulating water is circulated at a certain speed. Taking out the crucible, and preparing the ZTA particle-reinforced wear-resistant block with the controllable shrinkage rate of the metal matrix;

the structure schematic diagram of the ZTA particle-reinforced metal matrix shrinkage-controllable wear-resistant block of the present embodiment is shown in fig. 3, wherein fig. 3(a) is a truncated cone shape, and fig. 3(b) is a cylinder shape.

The shrinkage of the metal matrix of the wear-resistant block with the controllable metal matrix shrinkage prepared by the process can be measured by a drainage method, the shrinkage of the matrix is 25%, the matrix hardness of the reinforced block is 54.5HRC, the composite material has no cracks, and the large-particle ceramic and the wear-resistant block matrix are metallurgically bonded. The macroscopic photograph of the cross section of the obtained wear-resistant block with the controllable shrinkage rate of the metal matrix is shown in fig. 7, and fig. 7 illustrates that the reserved pores are uniformly distributed. According to the American ASTM-G65 standard and JBT7705-1995 standard, when the wear resistance is 1400m by using an MLG-130 wear machine test, the weight loss is 0.0520G, and the wear resistance is good.

The wear-resistant block with the controllable shrinkage rate of the ZTA particle-reinforced metal matrix prepared in the embodiment is used in a metal ceramic wear-resistant roller sleeve for treatment, and comprises the following steps:

the method comprises the following steps: the cooled wear-resistant block with the controllable shrinkage rate of the metal matrix and the prepared metal ceramic wear-resistant roller sleeve are subjected to synchronous heat treatment; wherein, the preparation of the metal ceramic wear-resistant roller sleeve adopts the existing preparation method.

Step two: the heat treatment process of the wear-resistant block comprises the following steps:

quenching: quenching the cooled wear-resistant block with the controllable metal matrix shrinkage rate, wherein the specific process comprises the following steps:

quenching temperature: 1050 deg.C

The heating rate is as follows: 9 ℃/min

And (3) heat preservation time: 2h

A cooling mode: air cooling

Annealing: the air-cooled abrasion-resistant block with controllable metal matrix shrinkage is tempered by the specific process,

tempering temperature: 600 deg.C

The heating rate is as follows: 9 ℃/min

And (3) heat preservation time: 2h

A cooling mode: cooling along with the furnace to obtain the metal ceramic wear-resistant roller sleeve.

Example 3

A wear-resistant block with a controllable metal matrix shrinkage rate, which adopts the same preparation device as that of the embodiment 1.

The preparation method of the wear-resistant block with the controllable metal matrix shrinkage rate in the embodiment specifically comprises the following steps:

step 1, preparing a wear-resistant block raw material with a controllable metal matrix shrinkage rate:

preparing a metal matrix and a reinforcing phase; the metal matrix is high-chromium cast iron alloy powder, and the high-chromium cast iron alloy powder comprises the following chemical components in percentage by mass: c: 3.0%, Si: 1%, Mn: 0.1%, Cr: 16%, Mo: 3%, and the balance of Fe and inevitable impurities; the reinforcing phase is ceramic reinforcing particles;

ceramic reinforcing particles in volume ratio: high-chromium cast iron alloy powder 1: 3; the ceramic reinforcing particles used in this example were oxide ceramic particles: ZTA granule, 10 mesh.

(1) The ZTA particles are washed to obtain cleaned ZTA particles.

(2) Weighing various powders for forming the high-chromium cast iron alloy powder according to the mixture ratio: high-carbon ferrochrome powder, ferromolybdenum powder, manganese powder and carbon powder are simultaneously filled into an industrial V-shaped powder mixer and mixed for 2 hours to obtain uniformly mixed high-chromium cast iron alloy powder;

(3) weighing the cleaned ZTA particles and the mixed high-chromium cast iron alloy powder in the step (2) according to the pre-calculated volume fraction of the ceramic reinforced particles, filling the ZTA particles and the mixed high-chromium cast iron alloy powder into a powder mixer, and fully mixing for 1h to obtain a mixed material;

step 2: filling

(1) Putting the mixed materials into a crucible, enabling the materials to account for four fifths of the total height of the crucible, and compacting the mixed materials in the crucible by using a steel column;

(2) filling ZTA particles in the residual space of the crucible to obtain a crucible filled with materials;

and step 3: heating of

(1) Loading the crucible filled with the materials into a medium-frequency induction heating machine, correcting errors of empirical parameters according to the calculated theoretical shrinkage rate of the high-chromium cast iron matrix, and setting the pressing depth of a control hydraulic device;

the cylindrical calculation method comprises the following steps:

after calculation, the depth of depression in this example is 25.64 mm.

(2) The medium-frequency induction heater automatically returns to an initial position after a pressure head of the hydraulic device reaches a preset pressing depth according to a set program; the temperature interval of the medium frequency induction heater is 1400 ℃. The depression rate is preferably 2mm/s and is maintained for 10s after depression to the calculated depression depth.

(3) Circulating water enters from the water inlet (lower part) and gradually rises until the whole cavity is filled, and then is discharged from the water outlet (upper part). Circulating water is operated in the whole process line to ensure that the cavity is filled with water, and the heating procedure is carried out after the circulating water is circulated at a certain speed. Taking out the crucible, and preparing the wear-resistant block with the controllable shrinkage rate of the metal matrix;

the shrinkage of the metal matrix of the wear-resistant block with the controllable metal matrix shrinkage prepared by the process can be measured by a drainage method, the shrinkage of the matrix is 42%, the matrix hardness of the reinforced block is 57HRC, the composite material has no cracks, and the large-particle ceramic and the wear-resistant block matrix are metallurgically bonded. According to the American ASTM-G65 standard and JBT7705-1995 standard, when the wear resistance is 1400m by using an MLG-130 wear machine test, the weight loss is 0.0492G, and the wear resistance is good.

The wear-resistant block with the controllable metal matrix shrinkage rate prepared in the embodiment is used for processing a metal ceramic wear-resistant roller sleeve, and comprises the following steps:

the method comprises the following steps: the cooled wear-resistant block with the controllable metal matrix shrinkage rate and the prepared plate hammer are subjected to synchronous heat treatment; wherein, the preparation of the plate hammer adopts the existing preparation method.

Step two: the heat treatment process of the wear-resistant block comprises the following steps:

quenching: quenching the cooled wear-resistant block with the controllable metal matrix shrinkage rate, wherein the specific process comprises the following steps:

quenching temperature: 1040 deg.C

The heating rate is as follows: 9 ℃/min

And (3) heat preservation time: 2h

A cooling mode: air cooling

Annealing: the air-cooled abrasion-resistant block with controllable metal matrix shrinkage is tempered by the specific process,

tempering temperature: 550 deg.C

The heating rate is as follows: 8 ℃/min

And (3) heat preservation time: 2h

A cooling mode: cooling along with the furnace to obtain the plate hammer.

Example 4

A wear-resistant block with a controllable metal matrix shrinkage rate, which adopts the same preparation device as that of the embodiment 1.

The preparation method of the wear-resistant block with the controllable metal matrix shrinkage rate in the embodiment specifically comprises the following steps:

step 1, preparing a wear-resistant block raw material with a controllable metal matrix shrinkage rate:

preparing a metal matrix and a reinforcing phase; the metal matrix is high-chromium cast iron alloy powder, and the high-chromium cast iron alloy powder comprises the following chemical components in percentage by mass: c: 3.0%, Si: 1%, Mn: 15%, Cr: 30%, Mo: 0.5%, the balance being Fe and unavoidable impurities; the reinforcing phase is ceramic reinforcing particles;

ceramic reinforcing particles in volume ratio: high-chromium cast iron alloy powder 1: 3; the ceramic reinforcing particles used in this example were carbide ceramic particles: tungsten carbide particles, 16 mesh.

(1) And cleaning the tungsten carbide particles to obtain the cleaned tungsten carbide particles.

(2) Weighing various powders for forming the high-chromium cast iron alloy powder according to the mixture ratio: high-carbon ferrochrome powder, ferromolybdenum powder, manganese powder and carbon powder are simultaneously filled into an industrial V-shaped powder mixer and mixed for 2 hours to obtain uniformly mixed high-chromium cast iron alloy powder;

(3) weighing the cleaned tungsten carbide particles and the high-chromium cast iron alloy powder mixed in the step (2) according to the pre-calculated volume fraction of the ceramic reinforced particles, filling the tungsten carbide particles and the high-chromium cast iron alloy powder into a powder mixer, and fully mixing for 1h to obtain a mixed material;

step 2: filling

(1) Putting the mixed materials into a crucible, enabling the materials to account for half of the total height of the crucible, and compacting the mixed materials in the crucible by using a steel column;

(2) filling tungsten carbide particles in the residual space of the crucible to obtain a crucible filled with materials;

and step 3: heating of

(1) Loading the crucible filled with the materials into a medium-frequency induction heating machine, correcting errors of empirical parameters according to the calculated theoretical shrinkage rate of the high-chromium cast iron matrix, and setting the pressing depth of a control hydraulic device;

the cylindrical calculation method comprises the following steps:

after calculation, the depth of depression in this example is 12.9 mm.

(2) The medium-frequency induction heater automatically returns to an initial position after a pressure head of the hydraulic device reaches a preset pressing depth according to a set program; the temperature interval of the medium frequency induction heater is 1400 ℃. The pressing rate was 0.5mm/s and was maintained for 60s after pressing to the calculated pressing depth.

(3) Circulating water enters from the water inlet (lower part) and gradually rises until the whole cavity is filled, and then is discharged from the water outlet (upper part). Circulating water is operated in the whole process line to ensure that the cavity is filled with water, and the heating procedure is carried out after the circulating water is circulated at a certain speed. Taking out the crucible, and preparing the wear-resistant block with the controllable shrinkage rate of the metal matrix;

the shrinkage of the metal matrix of the wear-resistant block with the controllable metal matrix shrinkage prepared by the process can be measured by a drainage method, the shrinkage of the matrix is 43 percent, the matrix hardness of the reinforced block is 54HRC, the composite material has no cracks, and the large-particle ceramic and the wear-resistant block matrix are metallurgically bonded. According to the American ASTM-G65 standard and JBT7705-1995 standard, when the wear resistance is 1400m by adopting an MLG-130 wear machine test, the weight loss is 0.0614G, and the wear resistance is good.

The wear-resistant block with the controllable metal matrix shrinkage rate prepared in the embodiment is used for processing a metal ceramic wear-resistant roller sleeve, and comprises the following steps:

the method comprises the following steps: the cooled wear-resistant block with the controllable shrinkage rate of the metal matrix and the prepared metal ceramic wear-resistant roller sleeve are subjected to synchronous heat treatment; the preparation method of the metal ceramic wear-resistant roller sleeve adopts the existing preparation method.

Step two: the heat treatment process of the wear-resistant block comprises the following steps:

quenching: quenching the cooled wear-resistant block with the controllable metal matrix shrinkage rate, wherein the specific process comprises the following steps:

quenching temperature: 1050 deg.C

The heating rate is as follows: 9 ℃/min

And (3) heat preservation time: 2h

A cooling mode: air cooling

Annealing: the air-cooled abrasion-resistant block with controllable metal matrix shrinkage is tempered by the specific process,

tempering temperature: 550 deg.C

The heating rate is as follows: 9 ℃/min

And (3) heat preservation time: 2h

A cooling mode: cooling along with the furnace to obtain the metal ceramic wear-resistant roller sleeve.

Example 5

A wear-resistant block with a controllable metal matrix shrinkage rate, which adopts the same preparation device as that of the embodiment 1.

The preparation method of the wear-resistant block with the controllable metal matrix shrinkage rate in the embodiment specifically comprises the following steps:

step 1, preparing a wear-resistant block raw material with a controllable metal matrix shrinkage rate:

the wear-resistant block with the controllable shrinkage rate of the metal matrix comprises ceramic reinforced particles and high-chromium cast iron alloy powder.

The high-chromium cast iron alloy powder comprises the following chemical components in percentage by mass: c: 2%, Si: 0.1%, Mn: 13%, Cr: 10%, Mo: 1% and the balance of Fe and inevitable impurities;

ceramic reinforcing particles in volume ratio: high-chromium cast iron alloy powder 1: 2; the ceramic reinforcing particles used in this example were oxide ceramic particles: mixture of ZTA particles and ZTA spheres, wherein ZTA (ZrO)₂-Al₂O₃) Particles, 1500 μm particle size, ZTA spheres (30% ZrO)₂-Al₂O₃) The particle size was 4 mm.

The wear-resistant block with the controllable metal matrix shrinkage rate prepared by the embodiment is used for manufacturing a vertical mill roller sleeve, namely for crushing hard materials such as cement.

(1) Washing the ZTA particles and the ZTA spheres to obtain cleaned ZTA particles and ZTA spheres, wherein the ZTA particles are prepared from the following raw materials in percentage by mass: ZTA spheres are 1: 1.

(2) Weighing various powders for forming the high-chromium cast iron alloy powder according to the mixture ratio: high-carbon ferrochrome powder, ferromolybdenum powder, manganese powder and carbon powder are simultaneously filled into an industrial V-shaped powder mixer and mixed for 2 hours to obtain uniformly mixed high-chromium cast iron alloy powder; the V-shaped powder mixer has the maximum loading capacity of 20 liters each time, the maximum loading weight of 20 kilograms and the rotating speed of a cylinder body of 9 r/min.

(3) Weighing cleaned ZTA particles and ZTA balls and the mixed high-chromium cast iron alloy powder in the step (2) according to the volume fraction of the ZTA particles and the ZTA balls calculated in advance, filling the materials into a powder mixer, and fully mixing for 1h to obtain a mixed material;

step 2: filling

(1) Putting the mixed materials into a crucible, enabling the materials to account for two thirds of the total height of the crucible, and compacting the mixed materials in the crucible by using a steel column;

(2) filling the residual space of the crucible with a mixture of ZTA particles and ZTA spheres to obtain a crucible filled with materials;

and step 3: heating of

(1) Loading the crucible filled with the materials into a medium-frequency induction heating machine, correcting errors of empirical parameters according to the calculated theoretical shrinkage rate of the high-chromium cast iron matrix, and setting the pressing depth of a control hydraulic device;

the cylindrical calculation method comprises the following steps:

after calculation, the depth of depression in this example was 15.29 mm.

(2) The medium-frequency induction heater automatically returns to an initial position after a pressure head of the hydraulic device reaches a preset pressing depth according to a set program; the heating temperature was 1300 deg.C, the pressing rate was 1.5mm/s, and the pressing was maintained for 30s after the calculated pressing depth.

(8) Circulating water enters from the water inlet (lower part) and gradually rises until the whole cavity is filled, and then is discharged from the water outlet (upper part). Circulating water is operated in the whole process line to ensure that the cavity is filled with water, and the heating procedure is carried out after the circulating water is circulated at a certain speed. Taking out the crucible, and preparing the wear-resistant block with the ZTA particles and the ZTA balls enhanced metal matrix and controllable shrinkage rate;

the structure schematic diagram of the ZTA particle and ZTA sphere reinforced metal matrix shrinkage controllable wear-resistant block of the present embodiment is shown in fig. 4, where fig. 4(a) is a truncated cone shape, and fig. 4(b) is a cylinder shape.

The wear-resistant block with controllable shrinkage of the ZTA particles and the ZTA balls reinforced metal matrix prepared in the embodiment is used in a metal ceramic wear-resistant roller sleeve for treatment, and comprises the following steps:

the method comprises the following steps: the cooled wear-resistant block with the controllable shrinkage rate of the metal matrix and the prepared metal ceramic wear-resistant roller sleeve are subjected to synchronous heat treatment;

step two: the heat treatment process of the wear-resistant block comprises the following steps:

quenching: quenching the cooled wear-resistant block with the controllable metal matrix shrinkage rate, wherein the specific process comprises the following steps:

quenching temperature: 1020 to 1050 DEG C

The heating rate is as follows: 8-9 ℃/min

And (3) heat preservation time: 2h

A cooling mode: air cooling

Annealing: the air-cooled abrasion-resistant block with controllable metal matrix shrinkage is tempered by the specific process,

tempering temperature: 400-600 DEG C

The heating rate is as follows: 8-9 ℃/min

And (3) heat preservation time: 2 to 4 hours

A cooling mode: cooling along with the furnace to obtain the metal ceramic wear-resistant roller sleeve.

Example 6

The process steps of this example are the same as example 1, except that the reinforcing particles are oxide ceramic particles: the ZTA spheres are mixed with 10-mesh ZTA particles, and the volume ratio is 1:1 and mixing.

Example 7

The process steps of this example are the same as example 4, except that the reinforcing particles are oxide ceramic particles: 16-mesh to 10-mesh ZTA particles in a volume ratio of 1:1 and mixing.

Example 8

The process steps of this example are the same as example 6, except that the reinforcing phase is ceramic reinforcing particles, the high-chromium cast iron alloy powder is used as a matrix, and the volume ratio of the ceramic reinforcing particles: high-chromium cast iron alloy powder 1: 2.5.

comparative example 1

The preparation process of the wear-resistant block prepared by the comparative example is the same as that of example 1, and the difference is that the shrinkage rate of the metal matrix of the wear-resistant block obtained by the programmed liquid phase sintering method is 32%.