镁合金热室压铸机压室耐热钢研究
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摘要
现在世界镁合金工程构件的98%用压铸方法生产,镁合金压铸的连续性对设备的高温高压工作零部件的使用寿命和安全性提出了苛刻的要求,如压室等热作件长期工作于630-700℃的镁合金液中,并要承受高达30-50 MPa的压力冲击、磨损和镁合金熔体的浸蚀。目前,热室压铸用高品质压室完全依赖高价进口,阻碍了镁合金热室压铸成套设备国产化进程、提高镁合金压铸件生产成本。因此,开发该种材料及其铸造成型技术具有显著的工程意义。
除更高的硬度外,体心立方的铁素体耐热钢比面心立方的奥氏体耐热钢具有更高的导热率、较低的热膨胀系数,从而具有更好的热疲劳和抗磨损性能,能够更好地满足镁合金热室压铸压室的服役环境对材料的苛刻要求。无镍高钴高钨铁素体耐热耐蚀合金钢,经淬火和高温回火后得到的马氏体具有很好的强韧性,较高的蠕变强度,良好的抗高温氧化性、耐磨性和耐镁熔体浸蚀性能;因无镍而从源头上杜绝了压室材料对镁液的污染。因此,该钢种是国内外镁合金热室压铸压室的首选材料。
本论文研究工作,旨在以含Cr 9-12%的铁素体耐热耐蚀合金钢为基础,研究开发无镍高钴高钨铁素体耐热耐蚀铸钢,使其满足在630-700℃设计使用温度下长期使用对性能的要求,使用性能(报废时间长于2年,打料次数超过十万次)达到与进口材料相当的水平。
为此,本文首先综述了耐热钢的研究概况,然后采用分子轨道法对铁素体耐热耐蚀合金钢的成分进行优化设计,并通过实验的方法评估最佳热处理工艺,制定了最终的热处理制度,为耐热钢的热处理工艺以及新材料的开发和市场提供指导。
通过成分优化设计的耐热钢,采用真空冶炼技术,先在真空感应电炉中熔融,再在电渣重熔炉,有效地防止了偏析,提高了冶炼纯度,根据淬火裂纹的产生机理,有效地避免了淬火裂纹的产生,研究结果表明在1060-1120℃空冷淬火,然后在650-720℃回火的马氏体组织具有良好的综合力学性能。
Nowadays, about 98 percent engineering magnesium-alloy components demand in the world are from die casting industry, rigorous requirements for sevice life and security of the equipment components in the high temperature and high pressure environment are brought forward due to the continuity of die casting for magnesium alloys, for example, the chamber is always employed in the magnesium alloys melting at 630-700℃, which is also subject to 30-50 MPa pressure impact, high abrasion and corruption from magnesium alloys melting. So far,high quality chambers are almost dependent on importation at expensive price,which has severely restricted the progress of the domestic complete magnesium-alloy die casting set of equipment and increases the cost of the magnesium-alloy castings. Therefore, it is very significant to work out eligible material and its foundry technology in the engineering field.
Besides higher hardness, the heat conductivity of body-centered cubic ferritic heat resisting steels is higher than that of face-centered cubic austenitic heat resisting steels, while the former thermal expansion coefficient is lower than that of the latter,so better heat fatigue and wear-resistant properties are showed in ferritic refractory steels, for which the rigorous requirements for the material of chambers are better satisfied. The high cobalt and high tungsten (9%-12%)Cr ferritic heat resisting and corrosion resisting steel without nickel introduced in this paper is such kind of novel material used as hot worked components in the die casting industry, the martensite after quench and temper at high temperature showes high obdurability and creep strength,favourable high temperature oxidation resistant property, abradability and corrosion resistance from magnesium alloys melting. The supercriterion of Fe impurity and Ni impurity dissolution in magnesium ingot are both prevented due to application of this steel without Ni,so it is the best choice for chambers of magnesium-alloy hot die-casting machines both at home and abroad.
The research in this paper is to exploit high cobalt and high tungsten (9%-12%)Cr ferritic heat resisting and corrosion resisting cast steels without nickel on the basis of (9%-12%)Cr ferritic heat resisting and corrosion resisting alloy steel. The modified 9-12%Cr cast steels in this paper is designed to apply between 630 and 700℃in a long time. The service performance arrives at equivalent level compared with the inward material. Namely, the out-of-service time is more than 2 years and the knockout times exceed100,000.
Therefore, the general situation in the ferritic heat resisting steels is retrospected first, then the chemical component are designed according to the calculation of crystal properties based on molecule orbit using discrete Variational Xa,final heat treatment regime is established through experiments, which could be used for reference in the similar material exploitation, its heat treatment and its market.
The vacuum melting technology is adopted for the refractory steel through component optimization,first the steel is molten in vacuum induction furnace and then remelted in the electroslag remelting furnace, by which the impurity qutient is improved and the component segregation is avoided effectively. After that the chamber is quenched between 1060 and 1120℃in the air and tempered between 650 and 720℃. The quenching cracks are prevented because of the technology according the cracks prevention mechanism. The research results show that the steel with martensite structure has excellent comprehensive mechanical properties.
除更高的硬度外,体心立方的铁素体耐热钢比面心立方的奥氏体耐热钢具有更高的导热率、较低的热膨胀系数,从而具有更好的热疲劳和抗磨损性能,能够更好地满足镁合金热室压铸压室的服役环境对材料的苛刻要求。无镍高钴高钨铁素体耐热耐蚀合金钢,经淬火和高温回火后得到的马氏体具有很好的强韧性,较高的蠕变强度,良好的抗高温氧化性、耐磨性和耐镁熔体浸蚀性能;因无镍而从源头上杜绝了压室材料对镁液的污染。因此,该钢种是国内外镁合金热室压铸压室的首选材料。
本论文研究工作,旨在以含Cr 9-12%的铁素体耐热耐蚀合金钢为基础,研究开发无镍高钴高钨铁素体耐热耐蚀铸钢,使其满足在630-700℃设计使用温度下长期使用对性能的要求,使用性能(报废时间长于2年,打料次数超过十万次)达到与进口材料相当的水平。
为此,本文首先综述了耐热钢的研究概况,然后采用分子轨道法对铁素体耐热耐蚀合金钢的成分进行优化设计,并通过实验的方法评估最佳热处理工艺,制定了最终的热处理制度,为耐热钢的热处理工艺以及新材料的开发和市场提供指导。
通过成分优化设计的耐热钢,采用真空冶炼技术,先在真空感应电炉中熔融,再在电渣重熔炉,有效地防止了偏析,提高了冶炼纯度,根据淬火裂纹的产生机理,有效地避免了淬火裂纹的产生,研究结果表明在1060-1120℃空冷淬火,然后在650-720℃回火的马氏体组织具有良好的综合力学性能。
Nowadays, about 98 percent engineering magnesium-alloy components demand in the world are from die casting industry, rigorous requirements for sevice life and security of the equipment components in the high temperature and high pressure environment are brought forward due to the continuity of die casting for magnesium alloys, for example, the chamber is always employed in the magnesium alloys melting at 630-700℃, which is also subject to 30-50 MPa pressure impact, high abrasion and corruption from magnesium alloys melting. So far,high quality chambers are almost dependent on importation at expensive price,which has severely restricted the progress of the domestic complete magnesium-alloy die casting set of equipment and increases the cost of the magnesium-alloy castings. Therefore, it is very significant to work out eligible material and its foundry technology in the engineering field.
Besides higher hardness, the heat conductivity of body-centered cubic ferritic heat resisting steels is higher than that of face-centered cubic austenitic heat resisting steels, while the former thermal expansion coefficient is lower than that of the latter,so better heat fatigue and wear-resistant properties are showed in ferritic refractory steels, for which the rigorous requirements for the material of chambers are better satisfied. The high cobalt and high tungsten (9%-12%)Cr ferritic heat resisting and corrosion resisting steel without nickel introduced in this paper is such kind of novel material used as hot worked components in the die casting industry, the martensite after quench and temper at high temperature showes high obdurability and creep strength,favourable high temperature oxidation resistant property, abradability and corrosion resistance from magnesium alloys melting. The supercriterion of Fe impurity and Ni impurity dissolution in magnesium ingot are both prevented due to application of this steel without Ni,so it is the best choice for chambers of magnesium-alloy hot die-casting machines both at home and abroad.
The research in this paper is to exploit high cobalt and high tungsten (9%-12%)Cr ferritic heat resisting and corrosion resisting cast steels without nickel on the basis of (9%-12%)Cr ferritic heat resisting and corrosion resisting alloy steel. The modified 9-12%Cr cast steels in this paper is designed to apply between 630 and 700℃in a long time. The service performance arrives at equivalent level compared with the inward material. Namely, the out-of-service time is more than 2 years and the knockout times exceed100,000.
Therefore, the general situation in the ferritic heat resisting steels is retrospected first, then the chemical component are designed according to the calculation of crystal properties based on molecule orbit using discrete Variational Xa,final heat treatment regime is established through experiments, which could be used for reference in the similar material exploitation, its heat treatment and its market.
The vacuum melting technology is adopted for the refractory steel through component optimization,first the steel is molten in vacuum induction furnace and then remelted in the electroslag remelting furnace, by which the impurity qutient is improved and the component segregation is avoided effectively. After that the chamber is quenched between 1060 and 1120℃in the air and tempered between 650 and 720℃. The quenching cracks are prevented because of the technology according the cracks prevention mechanism. The research results show that the steel with martensite structure has excellent comprehensive mechanical properties.
引文
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