摘要
在各类的磨损形式中,冲蚀磨损是较为常见的磨损形式之一,广泛的存在于现代化工业生产中。随着工业生产设备的大型化,冲蚀磨损造成材料的磨损增大,设备的维修费用增加,所造成的经济损失相当严重。因此,开发新的材料以及研究材料的冲蚀磨损过程和机理,对于材料的选用,提高冲蚀磨损工况下工件的使用寿命具有重要的意义。
本文通过聚氨酯(PU)改性酚醛树脂,制备了改性酚醛树脂粘结SiC颗粒复合材料,考察了改性酚醛树脂的剪切强度和拉伸强度,采用红外光谱分析了PU改性酚醛树脂的机理；测试了复合材料的硬度、弯曲强度及冲蚀磨损性能。通过对该复合材料冲蚀磨损形貌SEM的观察,分析并讨论了聚氨酯改性酚醛树脂粘结SiC颗粒复合材料的冲蚀磨损机理。研究结果表明：
偶联剂的加入能提高酚醛树脂的剪切强度和拉伸强度。当偶联剂KH-550的加入量为5wt%时,酚醛树脂的剪切强度和拉伸强度都达到了最好值,剪切强度达到11.38 MPa,拉伸强度达到了6.78 MPa。
一定量PU的加入,能够显著地提高酚醛树脂的剪切强度和拉伸强度。当苯磺酰氯加入量为11wt%,PU加入量为10wt%时,改性酚醛树脂的拉伸强度达到最大值11.1Mpa,剪切强度达到最大值15.8 MPa。同时,改性酚醛树脂粘结SiC颗粒复合材料的三点弯曲强度达到最大值44.9 MPa。
改性酚醛树脂粘结SiC颗粒复合材料的磨损量在90°冲蚀角处最大,在30°和60°处较小；而Q235钢在45°时的冲蚀磨损量最大,在30。和90°时较小。改性酚醛树脂粘结SiC颗粒复合材料的相对耐磨性能在45°时最好,达到1.06,然后随着冲蚀角度的增加而降低。
PU的加入显著提高了复合材料的冲蚀磨损性能,整体的冲蚀磨损率低于未改性酚醛树脂复合材料的冲蚀磨损率。在PU加入量为10wt%时,改性酚醛树脂复合材料的耐冲蚀磨损性能最好,冲蚀磨损率最低,达到0.2733mg/min。
当改性酚醛树脂粘结SiC颗粒复合材料在SiC颗粒大小及浆料中石英砂粒子粒度相同的情况下,随复合材料中SiC颗粒加入量的增大,其冲蚀磨损量先减小后增大,在SiC颗粒加入量为61wt%时达到最小值。
改性酚醛树脂粘结SiC颗粒复合材料冲蚀磨损率随着SiC颗粒尺寸的减小而增大。在SiC颗粒尺寸为30目时磨损率最小,相对耐磨性达到最大值1.75,在SiC颗粒尺寸为150目时冲蚀磨损率最大。
Erosion wear is a more common form in various forms of wear. It exists with a wide range in modern industrial production. With the industrialization of large-scale equipment, erosion caused increasing wear of materials, equipment maintenance costs and the economic losses very serious. Therefore, the development of new materials and research materials erosion process and mechanism for selection of materials and improve the life of the work pieces have a great significance.
In this paper, toughness of Phenolic resin was modified by Polyurethane, and prepared a modified Phenolic resin adhesive SiC particles composites, inspected the modified resin of the shear strength and tensile strength, Infrared spectral analysis of PU modified phenolic resin Mechanism; tested the hardness of composites, bending strength and erosion wear performance, through SEM analysis of morphology erosion and discussed polyurethane modified phenolic resin adhesive SiC particle composites erosion wear mechanism. Research shows that:
The addition of coupling agent can improve the mechanical properties of resin. When the coupling agent KH-550 for the addition of 5wt%, the phenolic resin of the shear strength and tensile strength have reached a good value, shear strength reached 11.38 MPa and the tensile strength reached 6.78 MPa.
A certain amount of PU accession, can significantly increase in phenolic resin tensile strength and shear strength, when the amount of benzenesulfonyl chloride for 11wt%, PU addition of 10wt%, the modified phenolic resin tensile strength reached Max 11.1Mpa, maximum shear strength 15.8MPa. At the same time, modified phenolic resin adhesive SiC particle composites achieved the maximum bending strength 44.9 MPa.
Wearing capacity of the modified phenolic resin adhesive SiC particles composite is biggest in 90°impact angle and small from 30°to 60°; but wearing capacities of the Q235 steel is biggest in 45°impact angle, in 30°and 90°is small. The relative wear resistance of the modified phenolic resin adhesive SiC particles composites in 45°impact angle is best, achieved 1.06, and then reduces along with the impact angle increasing.
The erosion wear performance of the composites marked enhancement when PU joined in, the overall wear rates of the modified phenolics composite materials were lower than the phenolics composites that didn't put in PU. When the quantity of PU joined 10wt%, the modified phenolics composite materials relative wear resistance to be best, the erosion wear rate was lowest, achieved 0.2733mg/min.
When the modified phenolic resin adhesive SiC particles composites materials in the SiC particles size and the particles size of sands in the slurry in same situation; As the SiC particles quantity joined in the composite enlargement, the wearing capacity reduced first and then increased; when the SiC particles joined the quantity was 61wt%, the wearing capacity achieved the minimum value.
The wear rate of the modified phenolic resin adhesive SiC particles composites increased along with the SiC particle sizes reduced. The wear rate is smallest and the relative wear resistant reached maximuml.75 when the SiC particle size was 600μm, wear rate is biggest when the SiC particle size was 100μm.
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