汽车用HAl62-4-3-0.1同步器齿环的研制
摘要
通过调整合金的成分，配制了添加Al、Mn、Si、Fe和Re的复杂黄铜合金，比较两种不同的铸造工艺，选取经电磁搅拌的铸坯，在GLEEBLE-1500热模拟机上模拟合金的高温屈服强度σ_s，并对合金进行热处理正交实验，用金相显微镜、扫描电镜观察和透射电镜分析合金不同状态下的显微组织和结构，并借助HP-134工作站和相应的软件模拟不同加工工艺下的复杂黄铜合金的锻压变形过程。研究结果表明：Al含量可以改变复杂黄铜中α相和β相的体积百分数，提高合金的硬度，改善合金的耐磨性，但Al含量一般不能超过3.5％，否则会出现有害的γ相，降低合金韵性能；添加微量元素Mn、Fe、Si可在复杂黄铜合金晶内形成Mn_5Si_3、Fe_3Si、Fe_3Al硬质相，不但促进非均匀形核，使合金晶粒细化，而且它们弥散分布在基体表面，使合金磨损时产生三体研磨，提高合金的耐磨性；稀土是一种很好的细化剂，但熔炼时必须保证稀土的含量，一般不高于0.1％，否则会出现有害的富稀土相，降低合金的性能；对于复杂黄铜来说，淬火温度、保温时间、时效温度对合金的硬度影响显著，因此要合理的控制热处理工艺；耐磨性并不是与合金的硬度成正比，而是存在一个最佳耐磨值。实验证明：少量的α相+基体相β相+硬质颗粒相(Mn_5Si_3、Fe_3Si、Fe_3Al、)是理想的耐磨组织；计算机模拟的结果表明：铸态和挤压态合金在锻压时不同的是，铸态合金所需的锻压力比较小。合金在高温下塑性极好，但由于锭坯较小，合金降温极快，所以建议用高速锻压。
In this paper,high-tensile and wear resistant brasses added Al> Mn^ Fe^ Si and Re were prepared by adjusting the component of the alloys.The mechanical properties of this material at various high temperature were tested during the process of simulating .The microstructure of the alloys in different conditions were observed by optical microscope ,SEM and TEM. In this paper, the DEFORM?program was used to simulate the forging of special brasses.The results are shown: The percentage of a and P phase were adjusted by the content of Al,which must be controlled less 3.5%.The phase of Mn5Si3, Fe3Si, Fe3Al may not only decrease the grains size but also improve the wear resistance by distributing dispersed.The content of RE must be constrolled accurately less 0.1% lest forming the harmful phase of RE decreasing the properties of the alloys.Wear resistence was not proportal to the hardness ,In fact, little a phase and 3 phase adding some partical phase was a peferct structure of wear resistence. The plastic of high-tensile brasses was very good ,when being forged ,the speed of forging must be quick.
In this paper,high-tensile and wear resistant brasses added Al> Mn^ Fe^ Si and Re were prepared by adjusting the component of the alloys.The mechanical properties of this material at various high temperature were tested during the process of simulating .The microstructure of the alloys in different conditions were observed by optical microscope ,SEM and TEM. In this paper, the DEFORM?program was used to simulate the forging of special brasses.The results are shown: The percentage of a and P phase were adjusted by the content of Al,which must be controlled less 3.5%.The phase of Mn5Si3, Fe3Si, Fe3Al may not only decrease the grains size but also improve the wear resistance by distributing dispersed.The content of RE must be constrolled accurately less 0.1% lest forming the harmful phase of RE decreasing the properties of the alloys.Wear resistence was not proportal to the hardness ,In fact, little a phase and 3 phase adding some partical phase was a peferct structure of wear resistence. The plastic of high-tensile brasses was very good ,when being forged ,the speed of forging must be quick.
引文
1．国际铜加工业者协会(IWCC)年度报告，伸铜月报，1999，No．11
2．郭淑梅．汽车同步器齿环管材的研究与开发．铜加工高新技术文集．2000
3．《有色金属材料加工手册》编写组．重有色金属材料加工手册第一册．冶金工业出版社，1979
4．铜和铜合金金相图谱。洛阳铜加工厂金相组，1983
5．黄海波，孙扬善．汽车同步环材料的研究．汽车工程，1995年第3期
6．赵祖德，姚良均等．铜及铜合金材料手册．科学出版社，1993
7．[日]平尾宽等．耐磨高强度黄铜合金．铜加工，1996年第1期
8．[日]岩村卓郎等．耐磨性优良的齿轮用铜合金．铜加工，1996年第2期
9．郭淑梅，王硕．轿车同步器齿环用HMn59-2-1-0.5合金的组织和性能关系研究．2000中国有色金属学会合金加工学术委员会研讨会文集
10．郭淑梅．高强耐磨复杂铝黄铜HAL-5-4-2．铜加工，2001年第3期
11．赵志忠，毛志强．HMn62-3-3黄铜同步器齿环．金属科学与工艺，1991
12．洪澜，隋智通．稀土在铜和铜合金中的作用．稀土，1991
13．[日]瑥川二郎．稀土的最新应用技术，1985
14．刘余九．稀土．冶金工业出版社，1988
15．杜挺．稀土元素在金属材料中德作用与机理．中国有色金属学报，1996(6)：13
16．魏晓伟，曾明．稀土对铸造铜合金流动性和热裂倾向德影响．铸造技术，1997(3)：46
17.F.A.Sadykov,V.A.Valitov,and N.p.Barykin.The Infl(?)ence of Deformation Heat Treatmrnt on the Structure and Wear Resistance of CuZNPb Brass.Journal of Materials Engineering and Performance.Volume 6(1) February 1997-73
18．胡亚民，张驰．变速箱同步齿环圈的材料与成形工艺．汽车工艺与材料，1998
19．贾建军．EQ153汽车变速箱同步器齿环德精锻．锻压技术，1998
20．任书坤．五十铃汽车变速器的国产同步环失效分析．汽车工艺与材料，1995
21．郭淑梅，王硕．复杂黄铜的合金设计．云南冶金，1999，vol．28：15
22．陈存中．有色金属熔炼与铸锭．冶金工业出版社，1987
23．郭淑梅，王硕．轿车同步器齿环用水平连铸管工艺探讨．铜加工，2000年第4期
24．李落星．钛合金挤压变形模拟研究．中南大学博士学位论文，2000
25．汪锡孝．试验研究方法．湖南科学技术出版社，1988
26.Y. SSUN,G.W. LORIMER, and N.RIDLEY. Microstructure of High-Tensile Strength Brasses Containing Silion andManganese. Metallurgical Transactions A Volume 20A,JULY 1989-1199
27.Y. S. SUN, G. W. Lorimer and N.Ridley. Microstructure of Some high tesile brasses.Materials Science and technology. February 1989 vol.5
28.X.K.MENG,M.K.KANG,Y.Q.YANG,and D.H.LIU. The Formation Mechanism of Plate in Beta Cu-Zn and Cu-Zn-Al Alloys.Matellurgical and Materials Transactions A, vol 25A, DECEMBER 1994-2601
29.S.I.SELITSER and J.W.MORRIS jr. Substructure Formation during Plastic Deformation. Acta metal.mater, vol.42,No. 12,3985-3991,199
30.A.WAHEED,N.RIDLEY. Microstructure and wear of some high-tensile brasses. Journal Of Materials science 29(1994) 1692-1699.
31．张铁茂，丁建国．试验设计与数据处理．兵器工业出版社，1989
32．方亮，周庆德．从磨料运动方式研究三体磨损机理．
33.J.K.LANCASTER. Material-specific wear mechanisms: relevance to wear modeling.International Workshop on Wear Modelling. June 16-17, 1988.
34．李建明．磨损金属学．冶金工业出版社，1990
35．[日]上林锰等，李名洲译．耐磨性高强度黄铜系合金的特性．铜加工，1996
36.M. SUNDBER, R. SUNDBER, S. HOGMARK. Metallographic Aspects On Wear Of Special Brass. Wear, 115(1987) 151-165.
37.D. PADMAVARDHANI AND Y.V.R.K. PRASAD. Characterization of Hot Deformation Behavior of Brasses using Processing Maps: Parts Ⅱ. β Brass and α-β Brass. METALLURGICAL TRANSACTIONS A. VOLUME 22A, DECEMBER 1991-2993.
38.LI Luo-xing,Peng Da-Shu. Flow Stress Behavior of Cu13Zn Alloy Deformed at Elevated Temperature. J. CENT. SOUTH UNIV. TECHNOL, Dec. 2000,vol.7
39．彭大暑编著．金属塑性加工力学．中南工业大学出版社，1989
40.S.Kobayashi,S.I.Oh and T. Altan. Metal Forming and the Finite Element Method. New York, Oxford University Press, 1989
41．王祝唐，关廷栋，肖景容等．金属塑性成形理论．机械工业出版社，1989
42．吕丽萍．有限元及其在锻压过程中的应用．西北工业大学出版社，1989
43．乔端，钱仁根．非线性有限元及其在塑性加工中的应用．冶金工业出版社，1990
2．郭淑梅．汽车同步器齿环管材的研究与开发．铜加工高新技术文集．2000
3．《有色金属材料加工手册》编写组．重有色金属材料加工手册第一册．冶金工业出版社，1979
4．铜和铜合金金相图谱。洛阳铜加工厂金相组，1983
5．黄海波，孙扬善．汽车同步环材料的研究．汽车工程，1995年第3期
6．赵祖德，姚良均等．铜及铜合金材料手册．科学出版社，1993
7．[日]平尾宽等．耐磨高强度黄铜合金．铜加工，1996年第1期
8．[日]岩村卓郎等．耐磨性优良的齿轮用铜合金．铜加工，1996年第2期
9．郭淑梅，王硕．轿车同步器齿环用HMn59-2-1-0.5合金的组织和性能关系研究．2000中国有色金属学会合金加工学术委员会研讨会文集
10．郭淑梅．高强耐磨复杂铝黄铜HAL-5-4-2．铜加工，2001年第3期
11．赵志忠，毛志强．HMn62-3-3黄铜同步器齿环．金属科学与工艺，1991
12．洪澜，隋智通．稀土在铜和铜合金中的作用．稀土，1991
13．[日]瑥川二郎．稀土的最新应用技术，1985
14．刘余九．稀土．冶金工业出版社，1988
15．杜挺．稀土元素在金属材料中德作用与机理．中国有色金属学报，1996(6)：13
16．魏晓伟，曾明．稀土对铸造铜合金流动性和热裂倾向德影响．铸造技术，1997(3)：46
17.F.A.Sadykov,V.A.Valitov,and N.p.Barykin.The Infl(?)ence of Deformation Heat Treatmrnt on the Structure and Wear Resistance of CuZNPb Brass.Journal of Materials Engineering and Performance.Volume 6(1) February 1997-73
18．胡亚民，张驰．变速箱同步齿环圈的材料与成形工艺．汽车工艺与材料，1998
19．贾建军．EQ153汽车变速箱同步器齿环德精锻．锻压技术，1998
20．任书坤．五十铃汽车变速器的国产同步环失效分析．汽车工艺与材料，1995
21．郭淑梅，王硕．复杂黄铜的合金设计．云南冶金，1999，vol．28：15
22．陈存中．有色金属熔炼与铸锭．冶金工业出版社，1987
23．郭淑梅，王硕．轿车同步器齿环用水平连铸管工艺探讨．铜加工，2000年第4期
24．李落星．钛合金挤压变形模拟研究．中南大学博士学位论文，2000
25．汪锡孝．试验研究方法．湖南科学技术出版社，1988
26.Y. SSUN,G.W. LORIMER, and N.RIDLEY. Microstructure of High-Tensile Strength Brasses Containing Silion andManganese. Metallurgical Transactions A Volume 20A,JULY 1989-1199
27.Y. S. SUN, G. W. Lorimer and N.Ridley. Microstructure of Some high tesile brasses.Materials Science and technology. February 1989 vol.5
28.X.K.MENG,M.K.KANG,Y.Q.YANG,and D.H.LIU. The Formation Mechanism of Plate in Beta Cu-Zn and Cu-Zn-Al Alloys.Matellurgical and Materials Transactions A, vol 25A, DECEMBER 1994-2601
29.S.I.SELITSER and J.W.MORRIS jr. Substructure Formation during Plastic Deformation. Acta metal.mater, vol.42,No. 12,3985-3991,199
30.A.WAHEED,N.RIDLEY. Microstructure and wear of some high-tensile brasses. Journal Of Materials science 29(1994) 1692-1699.
31．张铁茂，丁建国．试验设计与数据处理．兵器工业出版社，1989
32．方亮，周庆德．从磨料运动方式研究三体磨损机理．
33.J.K.LANCASTER. Material-specific wear mechanisms: relevance to wear modeling.International Workshop on Wear Modelling. June 16-17, 1988.
34．李建明．磨损金属学．冶金工业出版社，1990
35．[日]上林锰等，李名洲译．耐磨性高强度黄铜系合金的特性．铜加工，1996
36.M. SUNDBER, R. SUNDBER, S. HOGMARK. Metallographic Aspects On Wear Of Special Brass. Wear, 115(1987) 151-165.
37.D. PADMAVARDHANI AND Y.V.R.K. PRASAD. Characterization of Hot Deformation Behavior of Brasses using Processing Maps: Parts Ⅱ. β Brass and α-β Brass. METALLURGICAL TRANSACTIONS A. VOLUME 22A, DECEMBER 1991-2993.
38.LI Luo-xing,Peng Da-Shu. Flow Stress Behavior of Cu13Zn Alloy Deformed at Elevated Temperature. J. CENT. SOUTH UNIV. TECHNOL, Dec. 2000,vol.7
39．彭大暑编著．金属塑性加工力学．中南工业大学出版社，1989
40.S.Kobayashi,S.I.Oh and T. Altan. Metal Forming and the Finite Element Method. New York, Oxford University Press, 1989
41．王祝唐，关廷栋，肖景容等．金属塑性成形理论．机械工业出版社，1989
42．吕丽萍．有限元及其在锻压过程中的应用．西北工业大学出版社，1989
43．乔端，钱仁根．非线性有限元及其在塑性加工中的应用．冶金工业出版社，1990