湿磨衬板新材质开发及冲击腐蚀磨损机理的研究
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摘要
我国冶金矿山(铁矿、金矿等)湿式球磨机衬板，一直采用高锰钢制作。70年代后期铜矿山部分采用橡胶衬板，引进大型磨机开始采用合金钢衬板。矿山湿式磨机衬板，使用工况条件恶劣。既受腐蚀又受冲击和磨损。高锰钢仅韧性高、耐冲击性能好，耐磨损、耐腐蚀性能较差。因此国内外近年来纷纷研制改性高锰钢、中碳合金钢、高铬铸铁等材质。查阅国内外文献表明，虽然各类材质都有报道，但使用效果均不理想，主要表现为寿命较短。这一方面是新材料发展过程中的问题，另一方面是新材料的质量及稳定性还存在一定问题。为适应冶金矿山严酷的工况条件，我们必须研制一种性能好、成本适中的新材料取代高锰钢。
通过对湿磨衬板的实际工作条件分析，湿式磨机衬板的材质，应具有较高的硬度、韧性及耐蚀性能；衬板工作层应尽可能为单相组织，并尽量提高电极电位；同时应尽可能降低成分偏析、减少有害杂质含量，以及净化晶界。当然，有些因素之间是相互矛盾的，如韧性和硬度之间。问题的解决在于，从成分、工艺、组织、性能的控制，寻求耐磨、耐蚀及耐冲击的最佳配合范围。
为了考查合金的耐磨耐蚀性能，对一系列合金经淬火回火处理后，进行腐蚀磨损试验。腐蚀磨损试验机的转速400转／分。在不同的介质(PH≈3)和不同的时间内，对低碳高合金钢、高锰钢和中碳合金钢进行了冲击腐蚀磨损性能的研究。实验表明，在模拟冶金矿山的实际工况条件下，低碳高合金钢具有优良的综合性能，寿命最长，是比高锰钢和中碳合金钢更适合冶金矿山的严酷工况条件的湿式磨机衬板新材质。
最后通过Hitachi-x-650扫描电子显微镜考察了低碳高合金钢、高锰钢和中碳合金钢试样的冲击腐蚀磨损表面形貌，并用Olympus光学显微镜进行了光学金相分析，对这三种钢的磨损机理进行一定的探讨。
The costs associated with wear processes place a significant burden upon many sectors of industry and the community. Several studies have indicated that the abrasion and corrosion in the coal and mineral processing industries are areas for research priority owing to their significant impact on metal wastage and maintenance costs. It was against this background that the present study was initiated, which had as its aim an evaluation of the methods currently used in the mining and mineral processing industries for determining the wear performance of plant and equipment components.
In this study, the resistance to high impact, corrosion and abrasive wear was determined for low carbon high alloy steel, and for comparison, the high manganese steel and the medium carbon alloy steel are also tested. The test was carried out using a modified MLD-10 tester. The test methodology very well simulates the working condition of metallurgical industry. And four mediums were used for comparison.
We discussed the behavior of corrosion-abrasion of the liner of wet-grinding machine in simulated metallurgical conditions. The results show that under the simulated slurry, the corrosion rate and the wear loss of the low carbon high alloy steel is better than the high manganese steel and the medium carbon alloy steel. And with the increased test time, the superiority of the low carbon high alloy steel was well illuminated. The worn surfaces of the three steels show that the mechanism of the low carbon high alloy steel is impact abrasion, the high manganese steel is impact-corrosion, and the medium carbon alloy steel is the heaviest impact-corrosion. Under the quartzite slurry, the low carbon high alloy steel is better than the other two steels at 2 hours, but at 8 hours, the manganese steel has a lower wear loss. We think that in quartzite slurry, the impact abrasion plays an important role. The manganese steel has a excellent ductility, so the wear loss of the manganese is lower.
通过对湿磨衬板的实际工作条件分析，湿式磨机衬板的材质，应具有较高的硬度、韧性及耐蚀性能；衬板工作层应尽可能为单相组织，并尽量提高电极电位；同时应尽可能降低成分偏析、减少有害杂质含量，以及净化晶界。当然，有些因素之间是相互矛盾的，如韧性和硬度之间。问题的解决在于，从成分、工艺、组织、性能的控制，寻求耐磨、耐蚀及耐冲击的最佳配合范围。
为了考查合金的耐磨耐蚀性能，对一系列合金经淬火回火处理后，进行腐蚀磨损试验。腐蚀磨损试验机的转速400转／分。在不同的介质(PH≈3)和不同的时间内，对低碳高合金钢、高锰钢和中碳合金钢进行了冲击腐蚀磨损性能的研究。实验表明，在模拟冶金矿山的实际工况条件下，低碳高合金钢具有优良的综合性能，寿命最长，是比高锰钢和中碳合金钢更适合冶金矿山的严酷工况条件的湿式磨机衬板新材质。
最后通过Hitachi-x-650扫描电子显微镜考察了低碳高合金钢、高锰钢和中碳合金钢试样的冲击腐蚀磨损表面形貌，并用Olympus光学显微镜进行了光学金相分析，对这三种钢的磨损机理进行一定的探讨。
The costs associated with wear processes place a significant burden upon many sectors of industry and the community. Several studies have indicated that the abrasion and corrosion in the coal and mineral processing industries are areas for research priority owing to their significant impact on metal wastage and maintenance costs. It was against this background that the present study was initiated, which had as its aim an evaluation of the methods currently used in the mining and mineral processing industries for determining the wear performance of plant and equipment components.
In this study, the resistance to high impact, corrosion and abrasive wear was determined for low carbon high alloy steel, and for comparison, the high manganese steel and the medium carbon alloy steel are also tested. The test was carried out using a modified MLD-10 tester. The test methodology very well simulates the working condition of metallurgical industry. And four mediums were used for comparison.
We discussed the behavior of corrosion-abrasion of the liner of wet-grinding machine in simulated metallurgical conditions. The results show that under the simulated slurry, the corrosion rate and the wear loss of the low carbon high alloy steel is better than the high manganese steel and the medium carbon alloy steel. And with the increased test time, the superiority of the low carbon high alloy steel was well illuminated. The worn surfaces of the three steels show that the mechanism of the low carbon high alloy steel is impact abrasion, the high manganese steel is impact-corrosion, and the medium carbon alloy steel is the heaviest impact-corrosion. Under the quartzite slurry, the low carbon high alloy steel is better than the other two steels at 2 hours, but at 8 hours, the manganese steel has a lower wear loss. We think that in quartzite slurry, the impact abrasion plays an important role. The manganese steel has a excellent ductility, so the wear loss of the manganese is lower.
引文
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[19] 徐志明等．悬浮铸造高锰钢的组织与性能研究．钢铁，No．5，1995
[20] 孙世怀等．铸造，No．6，1987
[21] 隋金玲等．变质对中锰钢组织和性能的影响．金属热处理，No．1，1996
[22] 黄金亮等．矿山机械，No．3，1993
[23] 吕振林、邓月芹等．中铬铸钢及其在湿式磨机衬板上的应用．热加工工艺，No．6，1995
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[28] K. Wellinger. Wear, Vol. 11, No.3, 1968
[29] B.J. Noeal and A. Ball. Wear of Materials, 1983, 148～152
[30] 刘英杰．金属磨损．清华大学机械工程系金属材料教研组，1984，8，4
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[33] J. Larsen-Basse and B. Premaratne. Wear of Materials, 1983, 161～166
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[38] C. Epero. Wear, Vol.214, No.3, 1991
[39] R.L. Denis. Wear, Vol.214, No.1, 1998
[40] 刘家浚．材料磨损原理及其耐磨性．清华大学出版社，1993
[41] Rabinowich. E. Friction and Wear of Materials, 1965, 186～190
[42] 托马晓夫，H．Ⅱ．金属腐蚀及其保护的理论．中国工业出版社，1964
[43] Krupina, E.M. Protection of Matals, 19(1984), 689～699
[44] 史晋宏．腐蚀磨损影响因素及腐蚀磨损机理研究．中国农机院研究生论文，1984
[45] 罔则良等．防蚀技术，35(1986)，270～275
[46] Petrov, L.N. and Osadchuk I.P. Protection of Metals, 19(1983), 451～454
[47] Schoor, M., et al. Metallic Corrosion Proceedings-8th ICMC, 1980,1384
[48] Heidemeyer, J., Wear, 66(1981), 379～387
[49] Jones, D.A., Journal of Metals, No.6, 1985, 20～23
[50] 董允，林晓娉，姜晓霞．铬、钼对不锈钢腐蚀与腐蚀磨损性能的影响．机械工程材料，Vol．21，No．6，1997
[51] 林惠国等编著．钢的奥氏体转变曲线—原理、测试与应用．机械工业出版社
[52] 潘传宏．铸态奥氏体—贝氏体钢的冲击磨损性能．机械工程材料，2001，25(12)：32～33．
[53] 陈颜堂，白秉哲，方鸿生．中低碳空冷贝氏体钢的冲击磨损性能．钢铁研究学报，2001，13(3)：40～43．
[54] 吕振林，邓月声，饶启昌．马氏体球墨铸铁腐蚀磨损特性研究．机械工程材料，2001，25(5)：32～35．
[55] 仝健民，张伟良．高铬铸铁中残余奥氏体对冲击疲劳磨损的影响．机械工程材料，1994，30(6)：103～107．
[56] White C H, Honeycom be R W K.[J]. J Iron Steel Inst, 1962,200:457
[57] Roberts W N. [J]. TMS-AIME, 1964, 230:372
[58] Raghaan K S, Sastri A S. [J]. OM are inkowskiM J.TMS-AIME,1969,245:1569
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