原位冶金碳化钨复合材料研究
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摘要
由于传统粉末冶金制备WC系硬质合金的工艺复杂,流程长,耗能大,成本高,并且WC颗粒具有本质遗传性,从而限制了其在某些领域的应用。为短流程快速制备WpC(WC+W2C)复合材料,本文采用W基合金粉体原料,研制开发了等离子原位冶金技术和自耗电极直流电弧原位冶金技术,实现了WpC复合材料高效低成本的原位制备。WC、W2C等硬质相从高温熔体中原位生成,体系洁净无污染,合金组织致密均匀,耐磨性能优良。原位冶金技术设备造价低廉,加工效率高,可控性强,更容易实现工业化生产。
本文采用等离子原位冶金技术和自耗电极直流电弧原位冶金技术在42CrMo截齿齿顶盲孔内和A1203耐火材料型腔内制备出了块体WpC复合材料。采用SEM、XRD、EDS、EMPA、TEM等对WpC复合材料组织结构、物相及成分进行了分析。采用摩擦磨损试验机测量了WpC复合材料的滑动磨损性能和固定磨料条件下的磨料磨损性能。
组织分析结果表明,采用等离子原位冶金技术和自耗电极直流电弧原位冶金技术在截齿齿顶盲孔内制备出的块体WpC复合材料的微观结构近似,相组成为WC、W2C、M6C (Fe3W3C)、γ-Fe以及少量的Cr7C3和(Fe,Ni)3C,合金和基体呈良好冶金结合,从结合界面向合金内部,依次为平面晶区、鱼骨状共晶区、十字花状树枝晶区。鱼骨状共晶主要物相为Fe3W3C(亮区)和7-Fe(暗区),十字花状树枝晶物相组成为Fe3W3C,这三个区域的总厚度一般不超过200μm；再向内一直到合金的中心,组织较均匀,其特点是具有四角到六角形分支的树枝晶—Fe3W3C分散分布于具有长条状结晶特点的基底7-Fe上,而具有规则三角形或四边形的硬质相晶粒—WC和W2C则具有集中生长的特点,晶粒尺寸约为0.5-20μm,以近似于包共晶转变的形式进行生长。
WpC复合材料在耐火材料型腔内成型由于降温速度慢,气体有充足时间上浮逸出,使得内部组织更加致密均匀,WC和W2C晶粒长得更大,最大的三角形晶粒边长超过70μm, Fe3W3C形貌和在截齿齿顶盲孔内成型的样品明显不同,晶粒较圆整,分支结构大大减少。
研究了纯w粉和纯C粉在直流电弧下的反应。在500A电流下,保证生成WC的W、C化学计量比的前提下,体系中加入质量百分数为4%的A1,可以得到纯相WC粉体,并呈现出层片状结晶的特点；其它条件相同,体系中加4%的Cu,则效果较差些,制备出的粉体中除含有WC外,还含有较多的W2C、WO3以及未反应的C等。在1000A电流下,Cu作反应助剂,符合化学计量比的W、C反应得到的D08样品为WC和W2C两相共存的致密烧结体,两相以共晶的形式成核与生长。
在等离子束流及直流电弧作用下,WC原位反应成核后,在熔体中生长时具有相似特征,皆以小平面的形式结晶生长。由于界面能的不同导致各晶面的生长速度不同,最终导致结晶呈现层片状的结构。
制备出的WpC复合材料的平均硬度都能达到HRA82以上,WC和W2C两相共存的致密烧结体D08样品平均硬度达HRA87.8。对合金内部不同物相的显微硬度分别进行分析发现,WpC相的硬度最高,能达到2000HV0.2以上,组织中的Fe3W3C相的硬度也能达到1100HV0.2以上,而基体相由于固溶了部分的合金元素也表现出具有较高的显微硬度,达到600-800 HV0.2左右。
采用两种原位冶金技术在截齿齿顶盲孔成型的P01样品、D04样品和直流电弧下耐火材料型腔成型的D05样品,在干滑动磨损条件下,淬火45#钢作对磨环,在250N,400r/min转速下,随时间延长,三个样品的耐磨损性能已和YG13C接近,磨损趋势也基本相同,P01和D05样品耐磨性相当,D04样品稍差；在转速为400r/min,磨损时间为2h的条件下,200N和250N载荷下三个样品的耐磨损性能较好,失重小于YG13C,300N载荷下除D05样品外,其余两个样品失重稍高于YG13C; WpC复合材料的耐磨性最高可达42CrMo钢的15倍以上。固定磨料磨损条件下,随载荷增大,所有试样的失重都增加；三个样品中,耐火材料型腔中成型样品耐磨性最好,在100N、125N载荷作用下耐磨性与YG13C相当,在150N载荷作用下耐磨性稍差；两种工艺在截齿齿顶盲孔内成型样品耐磨性相当,在三种试验载荷下耐磨性都比YG13C稍差。150N载荷下,三个合金试样的耐磨性都达到了42CrMo钢耐磨性的77倍以上,在较低载荷作用下与42CrMo钢的相对耐磨性更好,显示出优良的耐磨料磨损性能。
利用白耗电极直流电弧原位冶金法初步试制了WpC复合材料截齿刀头,WpC复合材料和截齿齿体呈现良好冶金结合,结合强度高。
Tungsten carbide (WC) is produced traditionally by powder metallurgy (PM) technology. The PM technology is complex, flow process is long, energy consumption and costs are fairly high, and WC particles have essential heredity, which limits its application in some areas. In order to prepare WpC(WC+W2C) composite materials rapidly, in this paper, we have developed plasma in-situ metallurgical technology and consumable electrode direct current (DC) arc in-situ metallurgical technology, and WpC composite materials were prepared efficiently and low costly by W based alloy powder. The WC, W2C crystals are generated and growed up in-situ in the high temperature melt pool. The reaction system is clean, the alloy's structure is compact and uniform, and wear-resistant properties of them are excellent. The devices of in-situ metallurgical technology are efficient in processing, low in cost and easy to control, it's more likely to be applied in industrial production processes.
In this paper, bulk WpC composite materials were prepared in 42CrMo cutting pick crest hole separately by plasma in-situ metallurgical technology (PISM) and consumable electrode DC arc in-situ metallurgical technology(CEDISM), and prepared in Al2O3 refractory cavity by CEDISM. The microstructure, phases and ingredients were examined separately by SEM, XRD, EDS and EMPA. The skimming wear performance and fixed abrasive wear performance of the WpC composite materials were measured by friction wear tester.
The structure analysis results reveal that the microstructure of the specimens those were prepared in cutting pick crest hole separately by the two preparation methods are approximate, the phases of the specimens are WC, W2C, M6C(Fe3W3C),γ-Fe, Cr7C3 and small amount of (Fe, Ni)3C, the alloy and substrate have excellent metallurgical bonding. From bonding area to internal alloy area, the microstructure shows in turn planar interface, eutectic region and cross shaped dendrite region. The phases of the herringbone shape eutectic are mainly Fe3W3C (bright area) andγ-Fe (dark area), the phase of the cross dendrite is Fe3W3C, the total thickness of the three regions is generally less than 200μm; From the cross dendrite region to alloy centre, the microstructure is uniform, the character of it is that Fe3W3C dendrite which has four to hexagonal branches distributed in theγ-Fe matrix which has long strips characteristics. Hard particles-WC and W2C have measured triangular or quadrilateral shape, tend to show concentrated growth, and the size is around 0.5-20μm, the growth form of them is approximate peritectic and eutectic transformation.
The internal microstructure of the WpC composite materials prepared in refractory cavity is more compact and uniform due to slow cooling rate and adequate time for gases escaping. The WC and W2C crystals grow larger and the length of a triangular crystal side can reach more than 70μm, Fe3W3C is more rounding and the branch structure of it is reduced greatly.
The reaction of the pure W and C powder in DC arc is also studied. With 500A electricity, when the stoichiometric ratio of WC is ensured,4% weight percentage Al is added to the reaction system, the pure WC powder can be obtained, and the crystal shape is lamellar; If 4% weight percentage Cu is added to the reaction system, and other conditions are same, the powder contains WC, W2C, WO3 and unreacted C element. With 1000A electricity, Cu is used as reaction assistant element; the dense sintering alloy of the D08 specimen with WC and W2C phases is obtained from W and C powder according with stoichiometric ratio. The nucleation and growth form of WC and W2C phases are eutectic.
Under the interaction of the plasma beam and DC arc, the characteristics of the above specimens are similar. The WC crystals in-situ react, then nucleate and grow up from melt pool, the WC crystals have facet growth form; the interfacial energy of each crystal face in the WC crystal is different, so the growth speed of each crystal face is different; the result is that the WC particles are lamellar in structure.
The average hardness of all the prepared WpC composite materials can reach more than HRA82, and the average hardness of D08 specimen is HRA87.8. The WpC phase has highest hardness and the microhardness of it can reach above 2000HV0.2; the microhardness of the Fe3W3C phase can reach above 1100HV0.2; the microhardness of the matrix can reach around 600-800 HV0.2 because of high solid solubility of alloy elements.
In the dry sliding wear condition, quenched 45# steel as the grinding ring, the specimens produced in the cutting pick crest hole separately by PISM and CEDISM and the specimen in the refractory cavity produced by CEDISM are studied. When the load is 250N and the relative slipping speed is 400r/min, the wear resistant performances of the three specimens are close to YG13C and the wear trends of them are similar with the time extended, the wear resistant performances of P01 and D05 specimens are similar and slightly better than D04 specimen; when the rotate speed is 400r/min and wear time is 2 hours, the weight losses of the three specimens are less than YG13C when the loads are 200N and 250N, and the weight losses of the three specimens are slightly higher than YG13C when the load is 300N, and the best anti-skimming wear resistant abilities of the three specimens can reach 15 times higher than the 42CrMo steel. In the fixed abrasive wear conditions, the weight losses of all the specimens increase with the loads increase; the anti-abrasive wear performance of the specimen produced in the refractory cavity is best among the three specimens, the wear performance of it is similar while comparing with YG13C under the loads of 100N,125N, and when the load is 150N, the wear performance of it is slightly worse than YG13C; the abrasive resistance of the two specimens produced in the cutting pick crest hole are similar, and the anti-abrasive resistance performances of them are worse than YG13C under the loads of 100N,125N and 150N. The anti-abrasive resistance abilities of all the three specimens are at least 77 times higher than 42CrMo steel, and the resistance performances of them are even better compared with 42CrMo steel when the loads are lower, so the three specimens show excellent abrasive wear resistance performances.
Preliminary trial-manufacture of WpC composite materials used in cutting picks were proceeded which was produced by CEDISM, the results shows that the bonding strength of the WC composite materials and substrate is excellent.
本文采用等离子原位冶金技术和自耗电极直流电弧原位冶金技术在42CrMo截齿齿顶盲孔内和A1203耐火材料型腔内制备出了块体WpC复合材料。采用SEM、XRD、EDS、EMPA、TEM等对WpC复合材料组织结构、物相及成分进行了分析。采用摩擦磨损试验机测量了WpC复合材料的滑动磨损性能和固定磨料条件下的磨料磨损性能。
组织分析结果表明,采用等离子原位冶金技术和自耗电极直流电弧原位冶金技术在截齿齿顶盲孔内制备出的块体WpC复合材料的微观结构近似,相组成为WC、W2C、M6C (Fe3W3C)、γ-Fe以及少量的Cr7C3和(Fe,Ni)3C,合金和基体呈良好冶金结合,从结合界面向合金内部,依次为平面晶区、鱼骨状共晶区、十字花状树枝晶区。鱼骨状共晶主要物相为Fe3W3C(亮区)和7-Fe(暗区),十字花状树枝晶物相组成为Fe3W3C,这三个区域的总厚度一般不超过200μm；再向内一直到合金的中心,组织较均匀,其特点是具有四角到六角形分支的树枝晶—Fe3W3C分散分布于具有长条状结晶特点的基底7-Fe上,而具有规则三角形或四边形的硬质相晶粒—WC和W2C则具有集中生长的特点,晶粒尺寸约为0.5-20μm,以近似于包共晶转变的形式进行生长。
WpC复合材料在耐火材料型腔内成型由于降温速度慢,气体有充足时间上浮逸出,使得内部组织更加致密均匀,WC和W2C晶粒长得更大,最大的三角形晶粒边长超过70μm, Fe3W3C形貌和在截齿齿顶盲孔内成型的样品明显不同,晶粒较圆整,分支结构大大减少。
研究了纯w粉和纯C粉在直流电弧下的反应。在500A电流下,保证生成WC的W、C化学计量比的前提下,体系中加入质量百分数为4%的A1,可以得到纯相WC粉体,并呈现出层片状结晶的特点；其它条件相同,体系中加4%的Cu,则效果较差些,制备出的粉体中除含有WC外,还含有较多的W2C、WO3以及未反应的C等。在1000A电流下,Cu作反应助剂,符合化学计量比的W、C反应得到的D08样品为WC和W2C两相共存的致密烧结体,两相以共晶的形式成核与生长。
在等离子束流及直流电弧作用下,WC原位反应成核后,在熔体中生长时具有相似特征,皆以小平面的形式结晶生长。由于界面能的不同导致各晶面的生长速度不同,最终导致结晶呈现层片状的结构。
制备出的WpC复合材料的平均硬度都能达到HRA82以上,WC和W2C两相共存的致密烧结体D08样品平均硬度达HRA87.8。对合金内部不同物相的显微硬度分别进行分析发现,WpC相的硬度最高,能达到2000HV0.2以上,组织中的Fe3W3C相的硬度也能达到1100HV0.2以上,而基体相由于固溶了部分的合金元素也表现出具有较高的显微硬度,达到600-800 HV0.2左右。
采用两种原位冶金技术在截齿齿顶盲孔成型的P01样品、D04样品和直流电弧下耐火材料型腔成型的D05样品,在干滑动磨损条件下,淬火45#钢作对磨环,在250N,400r/min转速下,随时间延长,三个样品的耐磨损性能已和YG13C接近,磨损趋势也基本相同,P01和D05样品耐磨性相当,D04样品稍差；在转速为400r/min,磨损时间为2h的条件下,200N和250N载荷下三个样品的耐磨损性能较好,失重小于YG13C,300N载荷下除D05样品外,其余两个样品失重稍高于YG13C; WpC复合材料的耐磨性最高可达42CrMo钢的15倍以上。固定磨料磨损条件下,随载荷增大,所有试样的失重都增加；三个样品中,耐火材料型腔中成型样品耐磨性最好,在100N、125N载荷作用下耐磨性与YG13C相当,在150N载荷作用下耐磨性稍差；两种工艺在截齿齿顶盲孔内成型样品耐磨性相当,在三种试验载荷下耐磨性都比YG13C稍差。150N载荷下,三个合金试样的耐磨性都达到了42CrMo钢耐磨性的77倍以上,在较低载荷作用下与42CrMo钢的相对耐磨性更好,显示出优良的耐磨料磨损性能。
利用白耗电极直流电弧原位冶金法初步试制了WpC复合材料截齿刀头,WpC复合材料和截齿齿体呈现良好冶金结合,结合强度高。
Tungsten carbide (WC) is produced traditionally by powder metallurgy (PM) technology. The PM technology is complex, flow process is long, energy consumption and costs are fairly high, and WC particles have essential heredity, which limits its application in some areas. In order to prepare WpC(WC+W2C) composite materials rapidly, in this paper, we have developed plasma in-situ metallurgical technology and consumable electrode direct current (DC) arc in-situ metallurgical technology, and WpC composite materials were prepared efficiently and low costly by W based alloy powder. The WC, W2C crystals are generated and growed up in-situ in the high temperature melt pool. The reaction system is clean, the alloy's structure is compact and uniform, and wear-resistant properties of them are excellent. The devices of in-situ metallurgical technology are efficient in processing, low in cost and easy to control, it's more likely to be applied in industrial production processes.
In this paper, bulk WpC composite materials were prepared in 42CrMo cutting pick crest hole separately by plasma in-situ metallurgical technology (PISM) and consumable electrode DC arc in-situ metallurgical technology(CEDISM), and prepared in Al2O3 refractory cavity by CEDISM. The microstructure, phases and ingredients were examined separately by SEM, XRD, EDS and EMPA. The skimming wear performance and fixed abrasive wear performance of the WpC composite materials were measured by friction wear tester.
The structure analysis results reveal that the microstructure of the specimens those were prepared in cutting pick crest hole separately by the two preparation methods are approximate, the phases of the specimens are WC, W2C, M6C(Fe3W3C),γ-Fe, Cr7C3 and small amount of (Fe, Ni)3C, the alloy and substrate have excellent metallurgical bonding. From bonding area to internal alloy area, the microstructure shows in turn planar interface, eutectic region and cross shaped dendrite region. The phases of the herringbone shape eutectic are mainly Fe3W3C (bright area) andγ-Fe (dark area), the phase of the cross dendrite is Fe3W3C, the total thickness of the three regions is generally less than 200μm; From the cross dendrite region to alloy centre, the microstructure is uniform, the character of it is that Fe3W3C dendrite which has four to hexagonal branches distributed in theγ-Fe matrix which has long strips characteristics. Hard particles-WC and W2C have measured triangular or quadrilateral shape, tend to show concentrated growth, and the size is around 0.5-20μm, the growth form of them is approximate peritectic and eutectic transformation.
The internal microstructure of the WpC composite materials prepared in refractory cavity is more compact and uniform due to slow cooling rate and adequate time for gases escaping. The WC and W2C crystals grow larger and the length of a triangular crystal side can reach more than 70μm, Fe3W3C is more rounding and the branch structure of it is reduced greatly.
The reaction of the pure W and C powder in DC arc is also studied. With 500A electricity, when the stoichiometric ratio of WC is ensured,4% weight percentage Al is added to the reaction system, the pure WC powder can be obtained, and the crystal shape is lamellar; If 4% weight percentage Cu is added to the reaction system, and other conditions are same, the powder contains WC, W2C, WO3 and unreacted C element. With 1000A electricity, Cu is used as reaction assistant element; the dense sintering alloy of the D08 specimen with WC and W2C phases is obtained from W and C powder according with stoichiometric ratio. The nucleation and growth form of WC and W2C phases are eutectic.
Under the interaction of the plasma beam and DC arc, the characteristics of the above specimens are similar. The WC crystals in-situ react, then nucleate and grow up from melt pool, the WC crystals have facet growth form; the interfacial energy of each crystal face in the WC crystal is different, so the growth speed of each crystal face is different; the result is that the WC particles are lamellar in structure.
The average hardness of all the prepared WpC composite materials can reach more than HRA82, and the average hardness of D08 specimen is HRA87.8. The WpC phase has highest hardness and the microhardness of it can reach above 2000HV0.2; the microhardness of the Fe3W3C phase can reach above 1100HV0.2; the microhardness of the matrix can reach around 600-800 HV0.2 because of high solid solubility of alloy elements.
In the dry sliding wear condition, quenched 45# steel as the grinding ring, the specimens produced in the cutting pick crest hole separately by PISM and CEDISM and the specimen in the refractory cavity produced by CEDISM are studied. When the load is 250N and the relative slipping speed is 400r/min, the wear resistant performances of the three specimens are close to YG13C and the wear trends of them are similar with the time extended, the wear resistant performances of P01 and D05 specimens are similar and slightly better than D04 specimen; when the rotate speed is 400r/min and wear time is 2 hours, the weight losses of the three specimens are less than YG13C when the loads are 200N and 250N, and the weight losses of the three specimens are slightly higher than YG13C when the load is 300N, and the best anti-skimming wear resistant abilities of the three specimens can reach 15 times higher than the 42CrMo steel. In the fixed abrasive wear conditions, the weight losses of all the specimens increase with the loads increase; the anti-abrasive wear performance of the specimen produced in the refractory cavity is best among the three specimens, the wear performance of it is similar while comparing with YG13C under the loads of 100N,125N, and when the load is 150N, the wear performance of it is slightly worse than YG13C; the abrasive resistance of the two specimens produced in the cutting pick crest hole are similar, and the anti-abrasive resistance performances of them are worse than YG13C under the loads of 100N,125N and 150N. The anti-abrasive resistance abilities of all the three specimens are at least 77 times higher than 42CrMo steel, and the resistance performances of them are even better compared with 42CrMo steel when the loads are lower, so the three specimens show excellent abrasive wear resistance performances.
Preliminary trial-manufacture of WpC composite materials used in cutting picks were proceeded which was produced by CEDISM, the results shows that the bonding strength of the WC composite materials and substrate is excellent.
引文
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