新型低造价高性能PDC钻头浸渍合金的研究
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摘要
作为石油钻井所用的聚晶金刚石钻头切削刃(以下简称PDC)所采用的超硬PDC,其使用寿命、抗剪切能力、抗耐磨性能,均取决于浸渍合金性能的优劣程度。铜合金由于具有良好的润湿性和优异的机械性能以及耐腐蚀性而获得了广泛应用。目前所使用的浸渍合金大多数为Cu-Ni-Mn合金。这种材料的成本高,抗拉强度较低,流动性差,熔点高。因此,研制高强度高耐磨的新型低造价高性能PDC钻头浸渍合金成为钻井工业生产有待解决的问题。
在此背景下,采用铸造法工艺制备出Cu-Ni-Sn-Mn-Fe系列浸渍合金以及用无压浸渍工艺制备WCp/铜合金基体系列复合材料,并利用金相观察、SEM、TEM、能谱分析及磨损率、硬度的测量等方法,研究了Cu-Ni-Sn-Mn-Fe系列浸渍合金和WC_p/Cu-Ni-Sn-Mn-Fe系列复合材料的组织和性能的影响。研究发现:
(1) Cu-Ni-Sn-Mn-Fe系列浸渍合金的铸态组织为明显的树枝晶组织:枝晶内是Cu、Ni原子富集的α相,枝晶间为溶质原子Sn富集的{Cu, Sn}固溶体。几种铜合金都存在较严重的Sn元素的枝晶偏析,必须经行适当的均匀化处理,消除树枝晶偏析,方可进行热态和冷态的压力加工。
(2)加入Fe元素后Cu-Ni-Sn-Mn合金的机械性能均有所提高。添加Fe元素可以起到组织细化和晶粒细化的效果,同时添加Fe的数量应该有所限制,在适宜范围内它可以发挥改善合金组织,提高合金性能的作用,但是过高的Fe含量(如5%Fe),反而会产生一些负面影响。
(3) 400℃时效5小时后A5浸渍合金中α-Cu相显著增多,其它峰的强度基本不变。其抗拉强度和硬度比铸态合金有所提高,而其延伸率和塑性较低。
(4)在WC_p/Cu-Ni-Sn-Mn-Fe系列复合材料中,骨架材料WC几乎完全能被Cu液所浸润并能与铜合金基体很好的结合,W元素和铜合金中的元素在基体中产生互扩散,形成Fe_3W_3C复式碳化物和Cu_(0.4)W_(0.6)化合物,且两者之间产生轻微的界面反应。
(5) WC颗粒是PDC钻头复合材料中主要的耐磨相,同时由于铜基体合金的高强度与高韧性形成了对颗粒的有力支撑。因此几种基体成分不同的WC_p/Cu-Ni-Sn-Mn-Fe复合材料具有良好的耐磨性能。WC_p/Cu合金复合材料中铜合金基体的磨损形貌呈现塑性变形、粘着、脆性剥落及犁削等特征。WC颗粒的磨粒磨损失效机制主要是微观切削和脆性剥落。
As polycrystalline diamond cutter (PDC) well bit, its service life, shearing resistance and abrasive resistance depend on its maceration alloy’s quality. Copper alloys have been the most widely used for maceration alloy of PDC well bit, because of its excellent wetting property, mechanical properties and corrosion resistance. Currently, Cu-Ni-Mn maceration alloys are widely used, but this kind of alloy has high cost, low tensile-strength, low fluidity property and high melting point. Therefore, the research on maceration alloy of PDC well bits is done by forcing on new type and low price copper alloys.
Based on this background, casting processing was adopted to prepare series of Cu-Ni-Sn-Mn-Fe alloys and pressureless infiltration technology was adopted to prepare series of WCp/Copper alloy matrix materials. In this dissertation, by means of metalloscopy, SEM, TEM, energy spectrum and the measurement of wear and hardness, the microstructure and properties of maceration alloys and composites are studied. It is found as follows:
(1) The cast structures of all Cu-Ni-Sn-Mn-Fe maceration alloys have three zones: Treelike crystal is inner layer consisted of Cu-Ni solid solution with rich Cu and Ni. Outer layer of treelike crystal is {Cu, Sn} phase with rich Sn. These alloys exist serious Sn segregation in the as cast structure by macro-observation. If these alloys need to undergo cold-working and hot-working treatment, they must be heat treated in order to eliminate Sn segregation.
(2) A little Fe added in Cu-Ni-Sn-Mn alloys made mechanical properties increase, because doped Fe refined the microstructure and the gain. However, when the Fe content reaches in some value (5% Fe), the action was not obvious.
(3) After 400℃aging four hours, there are much moreα-Cu phase formed in A5 alloy. And its strength and hardness were stronger than that of casting alloy, but its elongation percentage and plasticity were lower than that of as cast alloy.
(4) In WC_p/Cu-Ni-Sn-Mn-Fe composites, almost skeleton particles WC were able to be soaked by copper liquid, and had a strong interface bonding with copper matrix. At the same time, there were the interface solution and mass interdiffusion of Fe, Cu, W and C elements between part of WC particle and copper maceration alloy, and Fe_3W_3C compound and Cu_(0.4)W_(0.6) compound were formed.
(5) WC particle were main wear resistant phase in matrix materials, because of the strong strength and malleability of copper matrix alloys. Therefore, series of matrix materials have excellent wear resistances. The wear loss of copper maceration alloys are mainly caused by plastic deformation、ploughing and spalling properties, and the wear loss of WC particle are mainly caused by micro-cutting and brittle micro-peeling.
在此背景下,采用铸造法工艺制备出Cu-Ni-Sn-Mn-Fe系列浸渍合金以及用无压浸渍工艺制备WCp/铜合金基体系列复合材料,并利用金相观察、SEM、TEM、能谱分析及磨损率、硬度的测量等方法,研究了Cu-Ni-Sn-Mn-Fe系列浸渍合金和WC_p/Cu-Ni-Sn-Mn-Fe系列复合材料的组织和性能的影响。研究发现:
(1) Cu-Ni-Sn-Mn-Fe系列浸渍合金的铸态组织为明显的树枝晶组织:枝晶内是Cu、Ni原子富集的α相,枝晶间为溶质原子Sn富集的{Cu, Sn}固溶体。几种铜合金都存在较严重的Sn元素的枝晶偏析,必须经行适当的均匀化处理,消除树枝晶偏析,方可进行热态和冷态的压力加工。
(2)加入Fe元素后Cu-Ni-Sn-Mn合金的机械性能均有所提高。添加Fe元素可以起到组织细化和晶粒细化的效果,同时添加Fe的数量应该有所限制,在适宜范围内它可以发挥改善合金组织,提高合金性能的作用,但是过高的Fe含量(如5%Fe),反而会产生一些负面影响。
(3) 400℃时效5小时后A5浸渍合金中α-Cu相显著增多,其它峰的强度基本不变。其抗拉强度和硬度比铸态合金有所提高,而其延伸率和塑性较低。
(4)在WC_p/Cu-Ni-Sn-Mn-Fe系列复合材料中,骨架材料WC几乎完全能被Cu液所浸润并能与铜合金基体很好的结合,W元素和铜合金中的元素在基体中产生互扩散,形成Fe_3W_3C复式碳化物和Cu_(0.4)W_(0.6)化合物,且两者之间产生轻微的界面反应。
(5) WC颗粒是PDC钻头复合材料中主要的耐磨相,同时由于铜基体合金的高强度与高韧性形成了对颗粒的有力支撑。因此几种基体成分不同的WC_p/Cu-Ni-Sn-Mn-Fe复合材料具有良好的耐磨性能。WC_p/Cu合金复合材料中铜合金基体的磨损形貌呈现塑性变形、粘着、脆性剥落及犁削等特征。WC颗粒的磨粒磨损失效机制主要是微观切削和脆性剥落。
As polycrystalline diamond cutter (PDC) well bit, its service life, shearing resistance and abrasive resistance depend on its maceration alloy’s quality. Copper alloys have been the most widely used for maceration alloy of PDC well bit, because of its excellent wetting property, mechanical properties and corrosion resistance. Currently, Cu-Ni-Mn maceration alloys are widely used, but this kind of alloy has high cost, low tensile-strength, low fluidity property and high melting point. Therefore, the research on maceration alloy of PDC well bits is done by forcing on new type and low price copper alloys.
Based on this background, casting processing was adopted to prepare series of Cu-Ni-Sn-Mn-Fe alloys and pressureless infiltration technology was adopted to prepare series of WCp/Copper alloy matrix materials. In this dissertation, by means of metalloscopy, SEM, TEM, energy spectrum and the measurement of wear and hardness, the microstructure and properties of maceration alloys and composites are studied. It is found as follows:
(1) The cast structures of all Cu-Ni-Sn-Mn-Fe maceration alloys have three zones: Treelike crystal is inner layer consisted of Cu-Ni solid solution with rich Cu and Ni. Outer layer of treelike crystal is {Cu, Sn} phase with rich Sn. These alloys exist serious Sn segregation in the as cast structure by macro-observation. If these alloys need to undergo cold-working and hot-working treatment, they must be heat treated in order to eliminate Sn segregation.
(2) A little Fe added in Cu-Ni-Sn-Mn alloys made mechanical properties increase, because doped Fe refined the microstructure and the gain. However, when the Fe content reaches in some value (5% Fe), the action was not obvious.
(3) After 400℃aging four hours, there are much moreα-Cu phase formed in A5 alloy. And its strength and hardness were stronger than that of casting alloy, but its elongation percentage and plasticity were lower than that of as cast alloy.
(4) In WC_p/Cu-Ni-Sn-Mn-Fe composites, almost skeleton particles WC were able to be soaked by copper liquid, and had a strong interface bonding with copper matrix. At the same time, there were the interface solution and mass interdiffusion of Fe, Cu, W and C elements between part of WC particle and copper maceration alloy, and Fe_3W_3C compound and Cu_(0.4)W_(0.6) compound were formed.
(5) WC particle were main wear resistant phase in matrix materials, because of the strong strength and malleability of copper matrix alloys. Therefore, series of matrix materials have excellent wear resistances. The wear loss of copper maceration alloys are mainly caused by plastic deformation、ploughing and spalling properties, and the wear loss of WC particle are mainly caused by micro-cutting and brittle micro-peeling.
引文
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