Composite wear component produced by casting and consisting of a metal matrix whose working face or faces includes inserts which have a very high wear resistance, characterized in that the inserts consist of a ceramic pad, this ceramic pad consisting of a homogeneous solid solution of 20 to 80% of Al2O3 and 80 to 20% of ZrO2, the percentages being expressed by weights of the constituents, and the pad then being impregnated with a liquid metal during the casting.
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1. Composite wear component produced by classical or centrifugal casting and consisting of a metal matrix having a working face or faces including inserts which have wear resistance, wherein the inserts consist of a porous ceramic pad, the porous ceramic pad consisting of a homogeneous solid solution ceramic composite of 20 to 80% of Al2O3 and 80 to 20% of ZrO2, the percentages being expressed by weights of the constituents, and the porous ceramic pad being integrated into the metal matrix by impregnation of a liquid metal in the porous ceramic pad during the casting.
0. 12. Composite wear component produced by classical or centrifugal casting, said composite wear component comprising
a metal matrix having a working face or faces including inserts which have wear resistance, the inserts include a porous ceramic pad, the porous ceramic pad comprises a homogeneous solid solution of 20 to 80% of Al2O3 and 80 to 20% of ZrO2, the percentages being expressed by weights of the constituents, and the porous ceramic pad being integrated into the metal matrix by impregnation of a liquid metal in the porous ceramic pad during the casting.
2. Composite wear component according to
3. Composite wear component according to
4. Composite wear component according to
5. Composite wear component according to
6. Composite wear component according to claim 1 5, wherein the ceramic grains are manufactured by one of electrofusion, sintering and flame spraying.
7. Composite wear component according to claim 1 5, wherein the ceramic grains are joined integrally with the aid of an inorganic or organic liquid adhesive prior to the casting with the liquid metal with a view to the production of the ceramic pad .
8. Composite wear component according to
9. Composite wear component according to
10. Composite wear component produced by classical or centrifugal casting according to
11. Composite wear component according to
0. 13. Composite wear component according to
0. 14. Composite wear component according to
0. 15. Composite wear component according to
0. 16. Composite wear component according to
0. 17. Composite wear component according to
0. 18. Composite wear component according to
0. 19. Composite wear component according to
0. 20. Composite wear component produced by classical or centrifugal casting according to
0. 21. Composite wear component according to
0. 22. Composite wear component accordint to
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The present invention relates to a composite wear component produced by casting and consisting of a metal matrix whose wear face comprises inserts which have good wear resistance properties.
The invention relates especially to wear components employed in plants for grinding, crushing and conveying various abrasive materials which are encountered in industries such as cement factories, mines, metallurgy, electricity generating stations or various quarries. These components are often subjected to high mechanical stresses in the bulk and to a high wear by abrasion at the working face. It is therefore desirable that these components should exhibit a high abrasion resistance and some ductility, to be able to withstand the mechanical stresses such as impacts and to be capable optionally of being mechanical.
Given that these two properties are difficult to reconcile with one another in the same material, composite components have already been proposed which have a core made of relatively ductile alloy in which isolated inserts which have a good wear resistance are embedded.
Document EP-A-0476496 proposes this technique for the production of grinding wheels whose working face has set-in inserts made of chrome pig iron.
Since it is known that ceramic materials have good abrasion resistance properties, it is also known to employ these materials for improving the abrasion resistance of wear components.
Document EP-A-0575685 proposes the use of ceramic materials in a moulding by lost-wax precision casting of small wear components.
This well-known process employs wax models which must be melted to obtain the mould cavity which must be filled with metal; this mould itself is made of ceramic and not of a conventional sand.
According to this document a ceramic pad (wafer core) is formed first, with a spongy structure which has a three-dimensional network of open pores all of which communicate with one another. This ceramic pad is formed by pouring grains of ceramic materials into an appropriate mould and, next, a liquid adhesive with a good fluidity, for example a liquid resin which, after curing, retains the grains to form the ceramic structure. The ceramic material may consist of aluminium oxide or of zirconium oxide. After having been pre-impregnated with wax, this pad is placed in a mould intended to produce the wax model of the component. The wax model is then case and, lastly, the ceramic mould is produced by dipping the wax model in a ceramic slurry. The ceramic mould containing the wax model is then heated so as to melt the wax model. The wax thus flows from the ceramic mould but the pads inserted beforehand in the wax model remain adhesively bonded to the walls of the ceramic mould.
For the casting of metal in the ceramic mould the latter is preheated to a temperature of the order of 1150° C., generally under vacuum.
This known technique is limited, however, to lost-wax precision moulding. Moreover, the compatibility between the metal matrix and the ceramic structure, especially in terms of temperature behaviour, presents hardly any problems in the case of the applications mentioned in this document, given that, when the metal is being cast, the mould and the ceramic structure are preheated to a high temperature. In addition, the technique is limited to the production of very precise special components, which are sold at a very high price because the lost-wax moulding process itself is very costly.
The document “Ullmann's Encyclopedia of Industrial Chemistry” (1985), W. Gerhartz, VCH Verslagsgesellschaft, 5th Edition XP002023826, page 5 mentions compositions based on Al2O3—ZrO2 for grinding devices intended for conditioning cast products (billets and slabs).
The technique described above cannot as such be adapted to the manufacture of wear components of larger dimensions for application such as those encountered in plants for grinding, crushing or conveying abrasive materials, where the components generally have sections of at least 25 mm and often larger than 40 mm.
In addition, in accordance with the technique of the present invention it is not possible to cast, or at least it is difficult to envisage casting, components with thin sections, for example of less than 25 mm, because neither the mould nor the ceramic insert is preheated to high temperature before the metal is cast.
Furthermore, the component usually undergoes a subsequent heat treatment. There must therefore be some compatibility from the viewpoint of temperature behaviour between the ceramic material and the metal, to avoid cracking due to the thermal shocks when liquid metal is being cast over the ceramic inserts, and those that can be produced during the subsequent heat treatment and caused by the different expansion coefficients of both these materials.
It is necessary, furthermore, that the mechanical properties of the ceramic material should be adapted to those of the metal in order to produce a component whose properties correspond to the requirements of the specific application for which it is intended.
The aim of the present invention is to provide a composite wear component with ceramic inserts satisfactorily corresponding to the requirements listed above.
A second problem arises from the fact that, above a thickness of 25 mm of the ceramic material, poor infiltration of the metal is observed. Another objective of the present invention is to solve this second problem by proposing specific geometries of the composite wear component.
To meet the first objective the invention proposes a composite wear component produced by conventional or centrifugal casting. It consists of a metal matrix whose wear surface comprises inserts which have good abrasion resistance properties, these inserts being made of a ceramic material, itself composite, consisting of a solid solution or homogeneous phase of 20 to 80% of Al2O3 and 80 to 20% or ZrO2, the percentages being expressed by weights of constituents.
The ceramic material may additionally contain other oxides whose proportion by weight does not exceed 3 to 4%.
According to a first preferred embodiment of the present invention the composition of the ceramic material is the following:
55-60% by weight of Al2O3, and
38-42% by weight of ZrO2.
According to another preferred embodiment the composition of the ceramic material is the following:
70-77% by weight of Al2O3, and
23-27% by weight of ZrO2.
with
Manufacture of a Crusher Rotor
The ceramic material is prepared as in Example 1 but this time choosing a composition which gives preference to the expansion coefficient at the expense of hardness, that is to say by taking 40% of ZrO2 and 60% of Al2O3.
Given that the thickness is particularly considerable in this kind of component, a “honeycomb” form configuration is employed, as shown in
A composite component is thus produced with a hardness of approximately 1350 Hv with an expansion coefficient close to 9×10−6. The objective here is to decrease the risk of splits in the component because of the high impact level to which this type of component is subjected.
Beater
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