高性能汽车制动鼓的研制与开发

通过对失效汽车制动鼓的分析,发现普通灰铸铁制动鼓较易出现磨损严重或热疲劳裂纹情况,已不能满足现在汽车高负荷和高速度的要求.由于石墨具有高的热传导性,采用高C铸铁将会改善抗热疲劳性,但石墨的增加会使铸件强度下降,在高C合金中加入合金元素(Cr、Mo、Cu、Sn等)可使铸件强度和抗热疲劳性等性能得到兼顾,从而使制动鼓的使用寿命得到大幅度提高.     

合金元素对球墨铸铁抗热疲劳性能的影响

研究了合金元素对球墨铸铁抗热疲劳性能的影响。结果表明,就抗热疲劳性能而言,在本研究范围内,耐热球墨铸铁模具材料的较佳成分配比w为:5.0%Si、0.5%Mn0、.5%Mo、1.2%Cr。Si是影响材料热疲劳抗力的重要元素,对耐热球墨铸铁模具材料的抗热疲劳性能起着决定性作用,它的含量直接决定了耐热球墨铸铁模具材料热疲劳抗力的总体水平。Mo元素的加入能够使晶粒细化,其含量越多,则晶粒越细小,材料对热疲劳裂纹萌生和扩展的抗力就越强。     

一种热疲劳试验方法

试验采用高频感应平面加热方式,利用自行设计的可编程逻辑控制器,控制高频电流的大小、感应加热的速度、上限加热温度、喷水冷却时间、热疲劳周期等多参数,对灰口铸铁及其表面WC-Co涂层试件实施热疲劳试验,设计了在热疲劳试件表面用划定单元区域的方法,对单元区域测量热疲劳裂纹数量和长度,累计计算总热疲劳裂纹数量和长度,作为试件抗热疲劳性能较为定量的判定方法。用此方法判定了灰口铸铁、灰口铸铁表面激光熔敷WC-Co涂层及涂层激光熔敷参数的不同条件下试件的抗热疲劳性能。     

约束式铸铁热疲劳性能测试装置

介绍了约束式铸铁热疲劳性能测试装置,并试验性地测定了灰铸铁、CuCrMo 合金铸铁、球铁和蠕铁的抗热疲劳性能,其效果良好。     

W对Fe-Cr-Mo-W-V热锻模具堆焊合金组织与性能的影响

针对热锻模具工作条件及其失效形式,采用药芯焊丝气体保护堆焊方法制备Fe-Cr-Mo-W-V系热锻模具堆焊合金,采用金相组织观察、硬度测试、回火热处理、抗热疲劳裂纹和力学性能等多种试验方法,分析了W含量对堆焊合金显微组织、焊态硬度、热稳定性、热疲劳性能以及力学性能的影响。结果表明:Fe-Cr-Mo-W-V系堆焊合金的显微组织由板条马氏体+残余奥氏体组成。随着W含量的增加,堆焊合金焊态及550℃回火处理后所对应的硬度值逐渐增加,随着热处理时间的延长,堆焊层硬度逐步降低并趋于平缓。随着堆焊合金中W元素的增加,堆焊合金抗热疲劳裂纹性能逐渐降低,Fe-Cr-Mo-W-V系堆焊合金的抗拉强度略高于国外焊接材料Weld Mold 9650,断后伸长率略低于焊接材料Weld Mold 9650。     

蠕化率对蠕墨铸铁热疲劳行为的影响

采用V型缺口试样,通过对试样反复加热冷却,研究了不同蠕化率(55%、70%、90%)对蠕墨铸铁热疲劳行为的影响。结果表明,随着蠕化率的增加,蠕墨铸铁的抗热疲劳性能先升高后降低,当蠕化率为70%时,蠕墨铸铁抗热疲劳性能最佳。不同蠕化率,蠕墨铸铁的裂纹萌生和扩展机制具有显著差异。当蠕化率90%时,在V型缺口裂纹萌生明显,主裂纹沿着蠕虫状石墨生成二次裂纹,最后V型缺口凹陷成崩塌趋势;而蠕化率70%和55%时,V型缺口附近裂纹明显减少,仅在球状石墨尖端部位和基体组织产生少量微小裂纹,且裂纹没有明显扩展,产生裂纹倾向低,V型缺口凹陷未形成崩塌。     

冶金质量对铝合金疲劳性能影响的探讨

评述铝合金疲劳裂纹萌生研究现状及机制,阐述了典型铝合金及其合金元素对疲劳性能的影响规律,非金属夹杂、气孔、疏松及粗大第二相等对疲劳裂纹萌生的影响,得出通过控制合金元素含量、减少杂质、提高洁净度、改善变质效果和改进热处理等可有效改善铝合金的断裂韧性。     

铬锰合金铸铁的耐热性能研究

耐热试验证明:添加适量的锰或铬锰元素的合金铸铁材料,其抗氧化能力、氧化速率、抗热疲劳能力均优于灰铸铁,可以较大幅度地提高模具在热循环场合的使用寿命,具有明显的技术价值。     

汽车发动机缸体用铸铁材料的性能研究

通过添加一定量的Mn和Cr,对HT350进行改性,采用工频熔炼炉熔炼铸铁。研究了Mn和Cr添加量对铸铁性能的影响,结果表明:当添加0.6%Mn,0.4%Cr时,铸铁性能最佳,材料的抗拉强度为425.7 MPa,硬度为HBS 243,当载荷为700 N,摩擦时间为20 min时样品磨损量百分比为2.15%,2 000次热疲劳试验后主裂纹长度为0.63 mm。Mn和Cr元素的添加有利于组织内部珠光体的数量增加和细化,同时在表面形成MnFe_2O_3和Cr_2O_3的复合氧化膜,有助于材料力学性能、耐磨性能以及抗热疲劳性能的提高。     

球墨铸铁抗热疲劳性能的研究

研究了在不同的化学成分以及热处理条件下,不同基体组织的球墨铸铁的抗热疲劳性能.结果表明:铁素体基体球铁的抗热疲劳性能最好,珠光体、贝氏体基体球铁的抗热疲劳性能不如铁素体基体的球铁;加入合金元素后,铁素体球铁和珠光体球铁的抗热疲劳性能均有下降.     

V、Ti合金化对玻璃模具材料抗氧化及耐热疲劳性的影响

通过测试不同V/Ti比条件下蠕墨铸铁玻璃模具材料的抗氧化及热疲劳性能,研究了蠕墨铸铁的钒、钛合金化工艺,并探讨了影响这些性能的因素.结果表明,在V、Ti变化范围内,V/Ti比为1.63时蠕墨铸铁具有较均匀的铁素体基体+蠕虫状石墨组织,以及良好的热物性.     

Microstructure and wear properties of low-alloy phosphoric gray cast irons

The effects of various alloying elements on the microstructure and wear properties of phosphoric gray cast irons were examined. The wear properties of gray cast irons were examined with wear tests in the lubricated condition at various final loads and sliding speeds. It is found that the microstructure and the morphology and size of flaky graphite do not change much with a small addition of alloying elements such as V, Nb, Mo and Cr. However, the wear resistance of phosphoric gray cast iron is found to increase significantly with an increasing amount of alloying element. For a given amount of alloying element, it is found that V and Nb are very effective, whereas Mo and Cr are less effective in increasing the wear resistance of phosphoric gray cast iron. The increase in the hardness of steadite caused by the segregation of carbide-forming elements is found to be responsible for the excellent wear resistance of low-alloy phosphoric gray cast irons.     

Different thermal fatigue behaviors between gray cast iron and vermicular graphite cast iron

The initiation and propagation of thermal fatigue cracks in gray cast iron and vemicular graphite cast iron were investigated by Uddeholm method to reveal the complex thermal fatigue behaviors of cast iron. Differences of thermal fatigue behaviors of gray cast iron and vemicular graphite cast iron were observed and analyzed. It is found that the observed differences are related to the combination of graphite morphology and the oxidization of matrix. More oxidized matrix is observed in gray cast iron due to its large specific surface area. The brittle oxidized matrix facilitates the propagation of microcracks along the oxidization layer. By contrast, the radial microcracks are formed in vermicular graphite at the edge of graphite due to fewer oxidization layers. It indicates that the thermal fatigue resistance of gray cast iron is dominated by graphite content and morphology while that of vermicular graphite cast iron strongly relates to the strength of the matrix.

     

微合金梯度石墨铸铁玻璃模具材料研究

本文通过控制铸铁生产中的合金元素量、浇注温度、孕育剂量,得到在模具壁厚方向形成三级梯度石墨灰铸铁.利用SEM观察金相试样评价石墨形态、尺寸、分布;测试试样各梯度石墨区域的布氏硬度值评价铸铁的力学性能;观察热疲劳试样的疲劳裂纹的扩展评价试样的热力学性能.试验结果发现合金元素量V:0.11%～0.15%、Ti:0.15%～...     

Development of compacted vermicular graphite cast iron for railway brake discs

In the case of employing brake discs as a key component of mechanical brake equipment, the initiation of thermal cracking owing to repetitive thermal shock generated during braking may potentially lead to higher maintenance costs, worsened braking performance, and greater risk of railway accidents. The purpose of this study is to gain basic data to facilitate application of compacted vermicular (C. V.) graphite cast iron to brake discs in order to obtain high thermal crack resistance and improved lifetime. To this end, this study developed three types of C. V. graphite cast iron with differing content of key elements, including Ni, Cr, and Mo. Each test specimen underwent numerous tests for evaluation of materials characteristics, and the results were compared with those obtained for existing materials. The test results show that the thermal fatigue lifetime of material C is nearly double that of the conventional material. This demonstrates the suitability of material C as a material for brake discs in mid- to high-speed railway vehicles.     

合金元素对马氏体球墨铸铁腐蚀磨损的影响

研究了Si、Ni、Cu合金元素对球墨铸铁腐蚀磨损耐磨性的影响;结果表明,含硅量增加及添加铜、镍元素,马氏体球墨铸铁显微组织中碳化物数量减少,石墨球尺寸增大,腐蚀磨损耐磨性增加;磨损形貌观察表明,马氏体球墨铸铁腐蚀磨损机制以磨料磨损为主,腐蚀作用不明显。     

Thermal conductivity of cast iron-A review

This paper gives a brief introduction to the four research methods for the study on thermal conductivity of cast irons,including experimental measurement,statistical analysis,effective medium theory and numerical simulation.Recent studies on the thermal conductivity of various cast irons are reviewed through the influence of alloying elements,structural constituents,and temperature.The addition of alloying elements is the main reason that restricts the thermal conductivity of cast irons,especially spheroidal graphite cast iron.The connectivity of graphite has a significant effect on the thermal conductivity of flake and compacted graphite cast irons,semiquantitative and quantitative analysis of this factor is a key and difficult point in the study of thermal conductivity of cast irons.The thermal conductivities of different types of cast irons show varying degrees of dependence on temperature.This phenomenon is the combination of graphite and matrix,rather than just depending on graphite morphology.The study of the relationship between individual phase and temperature is the focus of future research.These summaries and discussions may provide reference and guidance for the future research and development of high thermal conductivity cast irons.     

Microstructure and fatigue properties of plasma transferred arc alloying TiC-W-Cr on gray cast iron

In this paper, TiC-W-Cr powders were alloyed on grey cast iron by plasma transferred arc (PTA). The alloying samples were characterized the microstructure, microhardness, fatigue life and fatigue crack growth. From the results, it is indicated that two distinguishing region: alloying zone, heat affected zone are formed on the surface after PTA alloying. The alloying zone mainly consists of primary austenite, martensite, a eutectic of (Fe,Cr)₇C₃ carbide and austenite as well as the uniformly distributed un-melted TiC particles. PTA alloying TiC-W-Cr eliminates the stress concentration at the edge of graphite and produced hard carbide, resulting in frequent crack deflection. As a result, the Weibull distribution of fatigue life demonstrates that PTA alloying TiC-W-Cr exhibits longer lives compared to matrix and PTA hardening without reinforcement, but more scattered. In addition, on the basis of the careful observation of fatigue crack growth, it is shown that the fatigue crack growth rate could be retarded by PTA alloying TiC-W-Cr at low stress intensity.     

Nb对灰铸铁热疲劳性能的影响

采用Uddeholm热疲劳方法测定了Nb对灰铸铁热疲劳性能的影响,试验结果表明：（1）Nb的加入能够提高灰铸铁的抗热疲劳性能,随着w（Nb）的增加,试样最大裂纹深度和宽度都逐渐减小;（2）由于Nb细化石墨使裂纹源减少和裂纹扩展途径变细,Nb元素能够改善材料表面经热疲劳处理后恶化的性能。     

Effect of Alloying Elements on Thermal Diffusivity of Gray Cast Iron Used in Automotive Brake Disks

The purpose of this work was to experimentally investigate the thermal diffusivity of four different gray cast iron alloys, regularly used to produce brake disks for automotive vehicles. Thermal diffusivity measurements were performed at temperatures ranging from room temperature to 600 °C. The influence of the thermal conductivity on the thermomechanical fatigue life is also briefly presented. The measurements were sensitive to the influence of the carbon equivalent and alloying elements, such as molybdenum, copper and chromium. Molybdenum, unlike copper, lowered the thermal diffusivity of the gray cast iron, and alloy E (without molybdenum), besides presenting a relatively low carbon equivalent content and an increase in the values of the thermal diffusivity, presented the best performance during the thermomechanical fatigue. The molybdenum present in alloys B and C did not fulfill the expectations of providing the best thermomechanical fatigue behavior. Consequently, its elimination in the gray cast iron alloy for this application will result in a significant economy.