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  • 专利说明
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    • 专利摘要:
    Wear part of a stone crusher or grinding mill, characterized in that the component of iron-based casting material (B) comprises a maximum of 60% by volume of durable inserts (A), which are at least 30 HRC hardness and contain at least 6% by volume of hard particles such as carbides, nitrides and oxides. In addition, the protection requirements 2-9.
    公开号:FI12710Y1
    申请号:FIU20190028U
    申请日:2019-02-20
    公开日:2020-08-14
    发明作者:Mikko Talvitie；Jari Ilmari Liimatainen
    申请人:Kerpua Solutions Oy；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION The invention is a wear part as described in the preamble of protective claim 1, where wear resistance is used in an iron-based cast base material - increasing special materials in the highest wear area of the wear part to increase the wear resistance of the structure. BACKGROUND OF THE INVENTION Crushing and grinding of minerals and aggregates use metallic, often cast, components that must withstand both mechanical loads such as shocks and fatigue loads and various forms of wear such as abrasion, erosion and impact wear. It is often necessary to optimize the different properties of materials depending on the mechanical loads present in the application, such as impact and fatigue load, on the one hand, and the type of wear, on the other.
    The problem with many traditional wear protection materials in the mineral and mining industries is the production of optimal microstructures as well as the limitations imposed by manufacturing technology. For example, the very commonly used Hadfield manganese steel (Mn content typically 11-20% by weight, carbon content
    1.0-1.8% by weight) is very tough but its abrasion resistance is not particularly good, especially if it is not strengthened by the surface pressures caused by the process. If hard particles such as carbides could be produced in the structure, the wear resistance would improve but at the same time the toughness of the structure would deteriorate. Because manganese steel components are manufactured - usually by casting, their carbide structure easily forms a very coarse and grain-continuous continuous, toughness-reducing network. Therefore, it is difficult to produce a carbide structure in manganese steel that increases the wear resistance without losing toughness. S 30 On the other hand, chromium alloy cast irons have been used in applications where component N is not subjected to significant mechanical loads or shocks such as sludge pumps, ro pipelines, small ball mills and impact beam crushers that crush the relatively fine mineral N. As their toughness is not sufficient N due to the large, partly continuous carbide networks, their use is not E 35 - however, it is possible in large crushers and grinding mills where © consumables are subjected to strong impacts and weary loads. QA
    O & H, rolled wear steels are used in selected S wear applications where> 40 wear resistance but also good toughness than normal structural steels is required. On the other hand, the material must have good hot workability because otherwise cracks will be created in the material during hot working, forging, and the production of this type of steel would not be possible. Powder metallurgical or rapidly solidified materials have been used for the production of very high-alloy materials, e.g. by thermostatic compression or melt deposition of a gas atomized powder. These methods allow a very high degree of alloying, a high volume fraction of very hard and wear-resistant carbides, and relatively good mechanical strength and toughness. This is due to a homogeneous microstructure and a suitable carbide structure with no long, continuous carbide networks or too large carbides that impair toughness and fatigue resistance. On the one hand, these methods are limited by higher costs due to the more expensive alloying, for example for carbide-forming alloying elements (e.g. Mo, Cr, V, W, Nb, Ti, Zr) and the higher costs of the manufacturing technique itself. For many wear components, wear is concentrated in certain areas whose protection would be sufficient to improve wear resistance for the entire component. If the component could be made of several different materials or if the wear-resistant material could be combined with, for example, a more cost-effective and mechanically reliable material, optimization of the component level would be possible. On the other hand, a very high strength is required from the joint because in crushers and large grinding mills, for example, the component is subjected to very high and continuous loads. If the connection had to be made to each component separately, the manufacturing costs of reliable connections would increase very high. Mechanical joining methods are very expensive due to the precise machining required for hard, hard-to-machine, wear-resistant materials. In addition, their reliability under fatigue loading may be poor. o If the mechanical connection is based on e.g. the mechanical or chemical N connection of the inserts to, for example, prefabricated cavities involves additional work steps and costs in their manufacture N, for example by drilling or cores. O 35 - In addition, many materials such as manganese steels or hardened N annealing steels are very difficult to machine and drill.
    I E Welding as a joining method is questionable, especially for large components e due to the welding costs of large joints. In addition, S 40 - most wear-resistant materials have poor weldability, making the quality of welds easily poor and the connection uncertain. 5 One way to join two materials together is by joint casting. However, the microstructure of the material to be joined in the joint casting technology corresponds to the microstructure of the cast material with the previously mentioned weaknesses such as large and coarse carbide structure, continuous carbide networks, inhomogeneity and casting defects. In joint casting, joint errors also easily occur at the interface of materials due to, for example, oxidation of the joint surfaces. In addition, due to differences in coefficients of thermal expansion and changes in specific volume associated with phase changes, very high residual stresses may arise in the structure. Welding can be used to better protect critical areas of wear parts locally with wear-resistant coatings. However, it is difficult to produce thick coatings with welding coatings. Welded coatings do not have a good mechanical properties, especially with high-alloy materials, and it also easily cracks, which can become larger during use and cause the coating to come loose or break. Welding coating also requires that the wear material that increases the wear resistance be available as a welding additive and that it, as well as the base material, is suitable for welding.
    Thermostatic compression is one way of joining two different materials together.
    However, its cost is very high due to the encapsulation of the individual components and the associated costs. In addition, many consumables are too large to be handled in thermostatic press units.
    - In summary, there is currently no technology to manufacture multi-material consumables for use in mineral processing equipment so that large amounts of wear-resistant steels containing suitably sized carbides can be used in wear areas reliably and cost-effectively combined with low-alloy, low-cost steels.
    Purpose of the invention
    O S The object of the invention is to eliminate the factors limiting the technical N performance and cost-effective manufacture of the products described above and to improve the wear resistance of O 35 crushers and grinding consumables by using wear-resistant N special materials together with cast steels.
    I & Summary of the Invention
    N S 40 - In the wear part of rock crushers or grinders according to the invention, according to Fig. 1, a sufficient amount of special materials (A) containing optimally sized hard particles are placed on surfaces requiring wear resistance of the iron-based cast base material (B) S with reliable joints. The microstructure of the special material (A) is illustrated in Figure 7 where the hard particles may be, for example, carbides, nitrides or oxides. In the wear part according to the invention, the special material (A) containing hard particles is placed in the areas of the highest consumption of the cast base material (B). The amount and density of the special material (A) in the areas of maximum wear is sufficient to increase - the wear resistance, however, so that the mechanical strength of the structure is sufficient based on the properties of the tough steel or iron used as the tough base material (B). Parts made of special material (A) are joined to cast iron-based base material (B) during the production of the base material in casting which allows good adhesion - by shaping the special material (A) and utilizing the coefficients of thermal expansion and specific volume of the special material (A) and base material (B). The iron-based cast base material (B) contains at least 70% by weight of iron, the remainder being the necessary alloying elements to obtain a sufficient level of properties of the base material such as strength, toughness and wear resistance. Suitable base materials include e.g. manganese steel and rejuvenated steel. Manganese steel is suitable for applications where very good toughness is required. For example, annealing steel with a hardness of more than HB 350 is suitable for applications where - the base material (B) is subjected to abrasive or low surface pressure abrasive wear where the manganese steel does not strengthen from the wear surface and the manganese steel wears rapidly. Combining the use of a cast base material (B) with a special material (A) removes size restrictions and also allows for easy product design. This is a significant advantage in large consumables, which often play a key role in the production of mines and aggregates, for example. The amount of carbides, nitrides or other ceramic particles in the special material (A) must be sufficient and of the correct distribution and composition to ensure sufficient wear resistance for the application. In addition to the particles, the material (A) has an o metallic matrix to give the wear-resistant material sufficient toughness and S manufacturability. The metallic matrix of the special material (A) may be based on an iron, N nickel, cobalt or titanium based material with <50% by weight of other alloying elements. The amount of carbides and other ceramic N particles of the special material (A) in the objects of compressive crushing should preferably be 10-25 l by volume. For impact beam crushing, an amount of carbide of 25-50 a% by volume can be used, especially in areas where the input size is small and when the inserts of the special material (A) are placed so that they are not directly exposed to S 40 impact wear.
    O S The placement of the special material (A) in the base material (B) so that it is surrounded by the base material (B) on all surfaces except the surface exposed to wear provides good mechanical support for the wear-resistant inserts during use.
    The length / diameter ratio of the wear-resistant special material (A) must be selected so that during an insert made of wear-resistant special material (A) shorter, its adhesion to the base material (B) remains good for a sufficiently long time. Preferably, the length / diameter ratio of the wear-resistant material insert should be> 1 during use, so depending on the thickness of the wear part to be manufactured and the area to be protected, the wear part should generally have a length / diameter ratio of 3: 1 to 10: 1 but also smaller length / diameter ratios such as at least 1.5: 1 before using the component as a consumable can be used. During use, as the base material (B) is modified to adhere to the special material (A), it improves due to the increase in the specific volume of several steels, but especially manganese steels as it is modified. Image list Figure 1 Consumables solution where special material (A) is placed on base material (B) Figure 2 Key dimensions of inserts made of special material (A). Figure 3 Consumables solution with metal intermediate layer (C) between special material (A) and base material (B) Figure 4 Cross-section of consumables solution according to Figure 3 with metal intermediate layer (C) between special material (A) and base material (B) Figure 5 Consumables solution with special material (A) is completely surrounded by the base material (B) after manufacture Figure 6A-6B Cross-section of the wear part solution according to Figure 5 when the base material (B) is worn out and the special material (A) appears on the wearing surface Figure 7 Microstructure of the special material (A) in which metal matrix ( a1) is hard particles (a2) such as carbides, nitrides and oxides N Detailed description of the invention
    Figures 1 and 2 show the crusher or grinder according to the invention = the consumable part and the arrangement of the materials. Inserts made of wear - resistant special material (A) have been added to the iron - based cast N 30 base material (B) in the region of the highest wear stress. Inserts made of special material (A) cover up to 80% of the surface of the higher N wear area so that the base material (B) forms a substantially continuous matrix around inserts made of special material (A). Inserts (A) made of special material must not account for more than 60 D% by volume of the volume of the entire wear part due to the deterioration of the mechanical strength of the structure.
    The gap between the wear-resistant inserts made of special material (A) and the base material (B) is minimized and there should be no non-metallic substances such as ceramic or polymer between the base material (B) and the inserts made of special material (A) which may crumble or detach during wear and thus weakens the joint. When both the insert made of the special material (A) and the surrounding base material (B) are metallic and in direct contact with each other, the most reliable connection for different load situations is obtained. If a ceramic or other non-metallic material is used between the special material (A) and the base material (B), crushed or ground material may penetrate during use and thus weaken the joint by gradually penetrating between the special material (A) and the base material (B).
    The aim is that the shrinkage of the base material (B) during solidification and cooling is greater than the shrinkage of the wear-resistant special material (A).
    This object is well achieved when using, for example, manganese steel as the base material (B), which has a high heat shrinkage compared to many wear-resistant steels or metal matrix composites. If the wear-resistant insert made of special material (A) is a bainitic or martensitic microstructure where it occurs during the cooling phase - the increase in specific volume associated with the phase change promotes strong adhesion to the base material (B) as the special material (A) expands after casting and / or heat treatment. The coefficient of thermal expansion of the base material (B) in the range 300-100 * C should be at least 5% higher than that of the special material (A) to ensure sufficient compressive stress to ensure its adhesion to the special material (A). The insert made of special material (A) adheres to the base material (B) partly by shrinkage, partly by tightening of the adhesion of the special material (A) and partly by metallurgical connection depending on the casting temperature used and the melting points and other metallurgical properties of materials (A) and (B). In order to ensure the quality of the joint, it is important for both the shrink joint, the form lock and the metallurgical joint that there are no LÖ non-metallic material layers between the base material (B) and the special material (A).
    O N For the base material (B), it is important that it has sufficient toughness I 35 in the casting state - because otherwise it will be micro-cracked in the post-casting shrinkage joint E as the casting shrinks around the insert. If O as a special material (A) is a material with a significant volume increase S during the cooling phase, special attention must be paid to the toughness of the base material (B) in the casting space 2. When using N 40 manganese steel as the base material, special care must be taken to avoid in a casting state and after heat treatment a situation in which the microstructure is rich in toughness - reducing grain boundary carbides. The composition of the base material (B) should be 8.0 to 20.0% by weight with respect to the manganese content. In addition, the carbon content must be in the range from 0.7 to 1.8% by weight and the carbide-forming alloys (Cr-Mo, Ti, W, Nb) must be less than 5% by weight.
    The amount of grain bound carbides can be reduced by minimizing the carbon content of manganese steel to less than 1.2% by weight, preferably less than 1.05% by weight, and by limiting the amount of carbide and nitride-forming alloys to less than 3% by weight.
    A metal sleeve or a metal intermediate layer (C) can be used around the wear-resistant insert, as shown in Figures 3 and 4, to protect the special material (A) from the thermal effects during casting and to support the formation of a reliable, tight connection.
    The metal intermediate layer (C), which is a low-strength metallic material, can also reduce the stresses formed in the cast base material as the cast base material (B) shrinks after casting around the metal intermediate layer (C) made of wear-resistant special material (A).
    The metal intermediate layer (C) around the special material (A) seals the joint - between the special material (A) and the base material (B).
    On the one hand, it must be strong enough to prevent the mineral to be treated from penetrating between the special material (A) and the base material (B) and on the other hand sufficiently flexible and soft to promote adhesion between the special material (A) and the base material (B).
    A suitable material is a low-alloy iron-based material available in very different product forms, such as low-alloy steel where the alloy is less than 15% by weight. The metal intermediate layer (C) can also be combined with the production of the special material (A) by being connected to the special material (A) via a metallurgical joint. In this case, a uniform combination of the special material (A) and the surrounding metal interlayer (C) can be used in the cast base material (B).
    The thickness of the metal intermediate layer (C) must be at least 0.1 mm in order to withstand the casting process and offer the described advantages in terms of adhesion.
    The ratio of the length (L) to the diameter (R) of wear-resistant inserts made of a special material (A) affects their adhesion in the molded base material (B). A good starting point for ensuring adhesion is o to use a length / diameter ratio greater than 5: 1 which ensures e even after very significant wear good adhesion b in the base material (B) as the length / diameter ratio decreases but also = length / diameter ratio 1.5: 1 can be used. - 35 - The shape of the inserts made of a special material (A) can be, for example, round, oval or rectangular in cross-section.
    O Inserts made of special material (A) must be limited in size so that the thermal stresses generated in their manufacture during S do not cause damage such as 2 cracks.
    In order to minimize the tendency of the inserts to crack during manufacture and in use N 40 - a circular cross-section is preferred so that the ratio of the minimum radius (Rmin) and maximum radius (Rmax), Figure 2, is at least 0.8 at different points in the cross-section of the insert (A).
    The insert made of special material (A) can also be made with various form-locking locks which improve the adhesion to casting, such as counter-releases or grooves on the outer surface of the insert made of special material (A). Their design must take into account the effect on the mechanical - durability during manufacture and use. Forms that are too sharp and cause high stress peaks during use or manufacture, for example on the outer surface of the special material (A), may cause cracks and impair the mechanical strength of the special material (A). On the other hand, if a metal intermediate layer (C) adhering to the outer surface of the special material (A) is used on the basis of the metallurgical joint, which has good toughness, grooves promoting shape locking can be used without the risk of breakage. Inserts made of special material (A) are positioned as shown in Figure 1 so that they are surrounded by the base material (B) except for the wear surface. Inserts made of special material (A) can also be placed according to Figures 5, 6A and 6B so that after manufacture they are completely surrounded by base material (B) according to Figure 6A but after the initial stage of base material (B) on the wear surface inserts made of special material (A) appear Figure 6B in accordance with to slow down wear. According to Figure 7, the special material (A) contains at least 6% by volume of hard particles (a2), such as carbides or nitrides, and their amount is adjusted according to the wear condition. In addition to hard particles such as carbides and nitrides, the special material (A) has a metallic matrix (a1) which can be based on iron, nickel, titanium or cobalt. The composition of the metallic matrix is adjusted to provide the desired hardness and toughness. The desired structure - may be based on the use of hard ceramic particles such as carbides, nitrides, oxides or a combination thereof as shown in Figure 7 in a metallic matrix. In this case, it is a so-called metal matrix composite. Alternatively, materials can be used where particles (a2) such as carbides are formed from the alloying elements therein in the heat treatment. Several tool steels with sufficient carbon and carbide-forming alloying elements, such as AISI D2 and AISI A11, are well suited for this purpose. However, the amount of their hard particles cannot be significantly increased above 30% by volume. In addition, it would be advantageous to heat-treat some of the special materials of this type b (A) after casting T, which sets requirements for the compatibility of their heat-treatment parameters with the N 35 base material (B).
    I n. In the special material (A), the size O of the carbides and other particles (a2) must be adjusted to obtain the correct properties. In order to obtain sufficient toughness S, the size of the particles (a2) as determined from the largest 2 dimensions of the particle should be limited to less than 300 μm, preferably less than 100 μm. N 40 - The importance of the size of the particles (a2) and in part the toughness determined by it depends on the operating environment, mechanical loads and wear environment. O OF O OF LÖ O OF OF
    I a a 00 OF O O O TUT O
    N D>
    权利要求:
    Claims (9)
    [1]
    Wear part of a stone crusher or grinding mill, characterized in that the component of iron-based casting material (B) comprises a maximum of 60% by volume of durable inserts (A), which is at least 30 HRC hardness and contains at least 6% by volume of hard particles such as carbides, nitrides and oxides.
    [2]
    Wear part according to Claim 1, characterized in that the cast steel or cast iron material (B) and the special material (A) are in direct contact with one another without non-metallic intermediate layers.
    [3]
    Wear part according to one of Claims 1 to 2, characterized in that the ratio between the length of the inserts (A) and the largest cross-sectional diameter is at least
    1.5: 1 before using the component as a wear part.
    [4]
    Wear part according to claim 1, characterized in that between the special material (A) and the base material (B) there is a metallic intermediate layer at least 0.1 mm thick (C) so that the intermediate layer (C) is iron-based material containing at least 85% by weight of iron.
    [5]
    Wear part according to one of Claims 1 to 4, characterized in that the coefficient of thermal expansion of the base material (B) within the temperature range 300-100 ° C is at least 5% greater than that of the special material (A).
    [6]
    Wear part according to one of Claims 1 to 5, characterized in that the inserts made of special material (A), determined from the total volume, are less than 1800 cm 3.
    [7]
    Wear part according to any one of claims 1-6, characterized in that the average size of the hardened particles (a2) of, for example, carbides, nitrides and oxides comprised of the durable material (A) is less than 300 μm.
    [8]
    Wear part according to one of Claims 1 to 7, characterized in that the ratio N between the smallest and largest cross-sectional diameter N of the special material insert (A) is at least 0.80. 3 N
    [9]
    Wear part according to one of Claims 1 to 8, characterized in that the base material (B) N is Hadfield's manganese casting number, whose carbon content is 0.7-1.8% by weight, manganese content E 8.0-20.0% by weight and the amount of alloying elements (Cr, Mo, Ti, W, Nb) which form carbides is below 5.0% by weight.
    S> = 5
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