化学镀/电弧喷涂复合材料模具制备技术研究
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摘要
本文采用电弧喷涂与化学复合镀相结合的方法制造金属基复合材料模具型腔，并通过浇铸颗粒增强树脂基复合材料和增加金属钢板外壳进行强化。研究了化学复合镀过程中五种因素：温度(℃)、pH值、SiC添加量(g/L)、稳定剂浓度(mg/L)、硫酸镍浓度(g／L)对化学复合镀沉积速率的影响，同时分析了以上五因素对耐磨性能的影响。采用正交试验方法对耐磨性化学复合镀Ni-P／SiC中具有代表性的五种因素进行了优化，得出了温度89℃、pH值5.1、SiC添加量6g/L、稳定剂浓度1.0mg/L及硫酸镍浓度32g/L的最佳方案。在电弧喷涂制造模具型腔的研究过程中，得出了金属铝丝材合理的喷涂工艺参数以获得均匀致密的喷涂层和较高的模具精度。随后采用热处理的方法提高电弧喷涂层与复合镀层的结合强度，获得350℃加热、1小时保温后随炉冷却的热处理工艺参数。
最后，采用以上试验所获得的各参数制造出复合材料化学试剂瓶模具，并采用有限元对复合材料模具散热性、强度进行了分析。
研究表明将化学复合镀与电弧喷涂制模技术结合起来，不仅可以大大提高模具的耐磨性能，延长其使用寿命，而且可以降低制模成本，缩短制模周期，是一项具有很好发展前景的快速模具制造技术。
To manufacture metal matrix composites mold cavity by integrating Electric arc spraying with composite electroless plating , to strengthen the mold by filling granules reinforced resin matrix composites and to back up the composites mold by using steel plate were presented in this paper. In the process of composite electroless plating, the effects on deposit velocity of five factors including temperature( C), pH value, SiC content (g/L) , stabilizer concentration (mg/L) and NiSO4 6H2O concentration (g/L) were studied. Five representative factors were optimized in wear resistance Ni-P/SiC composite electroless plating through orthogonal test method. The optimum combination of the five factors is it follows , temperature 89 C, pH value 5.1, SiC content 6g/L, stabilizer concentration 1.0mg/L and NiSO4 6H2O concentration 32g/L. The effects of each factor on wear resistance were analyzed and tested. While mold cavity was produced with electric arc spraying equipment, reasonable spraying parameters of Al to get uniform and compact layer as well as an accurate inner surface were obtained. Then by using heat treatment to increase the adhesion of metal spraying and composite electroless plating layer, the heat treatment technological parameter of 350 C, Ihour heat preservation then furnace cooling was achieved.
Finally, by using the parameters previously mentioned one composites plastic bottle mold was made. And by using FEM(finite element method) the thermal conductivity and strength of the composite mold were analyzed.
The study shows the method combining composite electroless plating with metal spraying mold making is not only to increase the wear resistance and to prolong operating life of composites mold, but to cut mold making cost and to shorten mold making cycle time as well. And it is also a rapid tooling with a bright future.
最后，采用以上试验所获得的各参数制造出复合材料化学试剂瓶模具，并采用有限元对复合材料模具散热性、强度进行了分析。
研究表明将化学复合镀与电弧喷涂制模技术结合起来，不仅可以大大提高模具的耐磨性能，延长其使用寿命，而且可以降低制模成本，缩短制模周期，是一项具有很好发展前景的快速模具制造技术。
To manufacture metal matrix composites mold cavity by integrating Electric arc spraying with composite electroless plating , to strengthen the mold by filling granules reinforced resin matrix composites and to back up the composites mold by using steel plate were presented in this paper. In the process of composite electroless plating, the effects on deposit velocity of five factors including temperature( C), pH value, SiC content (g/L) , stabilizer concentration (mg/L) and NiSO4 6H2O concentration (g/L) were studied. Five representative factors were optimized in wear resistance Ni-P/SiC composite electroless plating through orthogonal test method. The optimum combination of the five factors is it follows , temperature 89 C, pH value 5.1, SiC content 6g/L, stabilizer concentration 1.0mg/L and NiSO4 6H2O concentration 32g/L. The effects of each factor on wear resistance were analyzed and tested. While mold cavity was produced with electric arc spraying equipment, reasonable spraying parameters of Al to get uniform and compact layer as well as an accurate inner surface were obtained. Then by using heat treatment to increase the adhesion of metal spraying and composite electroless plating layer, the heat treatment technological parameter of 350 C, Ihour heat preservation then furnace cooling was achieved.
Finally, by using the parameters previously mentioned one composites plastic bottle mold was made. And by using FEM(finite element method) the thermal conductivity and strength of the composite mold were analyzed.
The study shows the method combining composite electroless plating with metal spraying mold making is not only to increase the wear resistance and to prolong operating life of composites mold, but to cut mold making cost and to shorten mold making cycle time as well. And it is also a rapid tooling with a bright future.
引文
1．靖永慧．浅析现代模具制造行业发展．模具技术．2001(5)：68～71
2．叶伟昌．模具技术的现状与进展．机械工艺师．1996(5)：31～33
3．李德群，张宜生．模具企业数字制造技术的现状与发展．CAD／CAM与制造业信息化．2003(7)：10～12
4. P.Fallbohmer, T.Altan,H.-K.Tonshoff, T.Nakagawa. Survey of the die and mold manufacturing industry. Journal of Materials Processing Technology 59(1996)158～168
5．陈衍祥，张海鸥，王桂兰等．快速成形及其在快速制模中的应用．机电工程1999．5152-155
6．郭九生，基于激光快速成形技术的快速工／模具制造，金属成形工艺，1998，16(3)：22
7. India S, Suzuki T. Fundamental study of metal infiltration in selective laser sintering. In Proceedings on the 8 Intern Conf On Rapid Prototyping, Tokyo, Japan, June 12～13,2000.401～406
8. Prinz F B, Weiss L E. Novel applications and implementations of shape deposition manufacturing. Progress in Rapid Prototyping Manufacturing and Rapid Tooling, Proceedings on the 1 st Intern Conf on Rapid Prototyping & Manufacturing '98, Beijing, China, July 21～23,1998.20～29
9. Song Y-A, Park S. Feasibility study of using 3D welding and milling process for rapid tooling .In Proceedings on the 8th International Conference on Rapid Prototyping, Tokyo, Japan, June 12～13, 2000. 438～443
10．颜永年，张人佶，单忠德等．快速模具技术的最新进展及其发展趋势．航空制造技术2002．4 17～21
11. Ming C. Leu, Wei Zhang. Research and Development in Rapid Prototyping and Tooling in the United States, Proceedings of the First International Conference on Rapid Prototyping and Manufacturing, BeiJing, China: 1998, 707-718
12. Doug smock, Robert Colvin, Peter Mapleston. Choice in Rapid Tooling Proliferate at Euromold. Modern Plastics International (Asian Edition), 1999,29(2): 92-97
13．中国模协技术委员会模具评定评述专家组．第九届中国国际模展现代模具制造技术评述．制造技术与机床．2002(12)：16～23
14．德国MCP/TAFA公司技术产品说明书．
15．胡传炘．热喷涂原理及应用[M]．北京：中国科学技术出版社，1994．
16．王海青．电弧喷涂技术及其应用．石油化工设备技术，1996，17(5)：59～63
17．王伊卿，赵文珍，唐一平等．电弧喷涂模具材料性能研究．中国机械工程，2000，11(10)：1112～1115
18．田保红，徐滨士，马世宁等．高速电弧喷涂粒子雾化特性实验研究．中国表面工
程．1999(1)15～19
19. Kelkar M. Hussary N. Scbein J. Optical diagnositics and molding of gas and droplet flow in wire arc spraying.ITSC'98[R]. Nice, France. 329～334
20．马跃进，唐国宝．液体喷砂工艺对电弧喷涂层结合强度的影响．中国农业大学学报，1997，2(2)；60～63
21．许洪斌，秦少波，张鹏等．快速模具制造动态联盟．机械工艺师，2000(10)：61～62
22．姜晓霞，沈伟．化学镀理论及实践．北京：国防工业出版社．2000．
23．胡信国．化学镀镍的发展前景．电镀与涂饰．1995(5)3
24．张立德．超微粉体制备与应用技术．中国石化出版社．2001．
25．李宁，袁国伟，黎德育．化学镀镍基合金理论与技术．哈尔滨：哈尔滨工业大学出版社．2000．
26. Doss,S.K. and J.D.Michaelsen: Paper presented at Electroless Nickel Conference Ⅱ(1982).
27. Gutzeit,G: Plating,46(1959)Oct.,pp.1158～1164
28．刘汝涛，高灿柱，隋华等．化学镀镍液中镍离子浓度的快速测定．材料保护，1998，31(10)：25～27
29．徐智谋，刘宏芳等．化学镀制备功能梯度材料的实验研究．复合材料学报，2000，17(4)：66～70
30. Feldstein N, et al.J.Elextrochem.Soc..1971,118～869
31. Ldas D,Chin T. Effects of bath stabilizers on electroless nickel deposition on ferrous substrates. Plating and Surface Finishing,1996,83(8):55～61
32．刘汝涛，高灿柱，杨景和等．影响化学镀镍稳定性因素的研究．表面技术，2001，30(1)10～12
33．阳范文．复合稳定剂在Ni-P化学镀中的应用．表面技术，1998，4：33～34
34．孙克宁，张弈林等．化学镀Ni-P工艺研究．电镀与环保，1998，18(3)：18～20
35．胡三媛，关永峰，徐方超．Ni-P-SiC复合镀工艺的优化．中国农业大学学报，2002，7(4)：39～42
36．孔兆利，乔尚琪，唐守秋．高耐磨性Ni-P-SiC化学复合镀层的制取．山东科学，1996，9(2)：18～22
37．韩克平，方景礼．硫脲稳定化学镀镍的机理．电镀与精饰，1996，18(3)：11～14
38．王迎春，马壮，吕广庶等．化学镀Ni-P合金的耐磨性研究．材料工程，2000，8：25～27
39．张恒，沈献民．Ni～P/SiC耐磨性化学复合镀工艺参数优化．郑州大学学报(理学版)．2004，36(3)：5～9
40．徐滨士，马世宁，刘世参等．高速电弧喷涂粒子速度和雾化特性研究。机械工程学
报，2000，30(1)：36～40
41．刘宪军，徐滨士，马世宁等．φ2mm丝材电弧喷涂系统的工艺参数和涂层性能研究．表面工程，1997．2：28～33
42．徐滨士，梁秀兵，马世宁等．新型高速电弧喷涂枪的开发研究．中国表面工程，1998．3：16～19
43. R.Simmonds. Electric-arc Metal Spraying with Low-metaling Alloys.German Plastics.
44．黄新民，邓宗钢．热处理工艺对化学沉积Ni-P-SiC复合镀层耐磨性的影响．材料保护，1996，29(3)：11～13
45. Steffens Hans Dieter, Matthias Wewel. Recent developments in vacuum arc spraying.Dortmund: Institute of technology.
2．叶伟昌．模具技术的现状与进展．机械工艺师．1996(5)：31～33
3．李德群，张宜生．模具企业数字制造技术的现状与发展．CAD／CAM与制造业信息化．2003(7)：10～12
4. P.Fallbohmer, T.Altan,H.-K.Tonshoff, T.Nakagawa. Survey of the die and mold manufacturing industry. Journal of Materials Processing Technology 59(1996)158～168
5．陈衍祥，张海鸥，王桂兰等．快速成形及其在快速制模中的应用．机电工程1999．5152-155
6．郭九生，基于激光快速成形技术的快速工／模具制造，金属成形工艺，1998，16(3)：22
7. India S, Suzuki T. Fundamental study of metal infiltration in selective laser sintering. In Proceedings on the 8 Intern Conf On Rapid Prototyping, Tokyo, Japan, June 12～13,2000.401～406
8. Prinz F B, Weiss L E. Novel applications and implementations of shape deposition manufacturing. Progress in Rapid Prototyping Manufacturing and Rapid Tooling, Proceedings on the 1 st Intern Conf on Rapid Prototyping & Manufacturing '98, Beijing, China, July 21～23,1998.20～29
9. Song Y-A, Park S. Feasibility study of using 3D welding and milling process for rapid tooling .In Proceedings on the 8th International Conference on Rapid Prototyping, Tokyo, Japan, June 12～13, 2000. 438～443
10．颜永年，张人佶，单忠德等．快速模具技术的最新进展及其发展趋势．航空制造技术2002．4 17～21
11. Ming C. Leu, Wei Zhang. Research and Development in Rapid Prototyping and Tooling in the United States, Proceedings of the First International Conference on Rapid Prototyping and Manufacturing, BeiJing, China: 1998, 707-718
12. Doug smock, Robert Colvin, Peter Mapleston. Choice in Rapid Tooling Proliferate at Euromold. Modern Plastics International (Asian Edition), 1999,29(2): 92-97
13．中国模协技术委员会模具评定评述专家组．第九届中国国际模展现代模具制造技术评述．制造技术与机床．2002(12)：16～23
14．德国MCP/TAFA公司技术产品说明书．
15．胡传炘．热喷涂原理及应用[M]．北京：中国科学技术出版社，1994．
16．王海青．电弧喷涂技术及其应用．石油化工设备技术，1996，17(5)：59～63
17．王伊卿，赵文珍，唐一平等．电弧喷涂模具材料性能研究．中国机械工程，2000，11(10)：1112～1115
18．田保红，徐滨士，马世宁等．高速电弧喷涂粒子雾化特性实验研究．中国表面工
程．1999(1)15～19
19. Kelkar M. Hussary N. Scbein J. Optical diagnositics and molding of gas and droplet flow in wire arc spraying.ITSC'98[R]. Nice, France. 329～334
20．马跃进，唐国宝．液体喷砂工艺对电弧喷涂层结合强度的影响．中国农业大学学报，1997，2(2)；60～63
21．许洪斌，秦少波，张鹏等．快速模具制造动态联盟．机械工艺师，2000(10)：61～62
22．姜晓霞，沈伟．化学镀理论及实践．北京：国防工业出版社．2000．
23．胡信国．化学镀镍的发展前景．电镀与涂饰．1995(5)3
24．张立德．超微粉体制备与应用技术．中国石化出版社．2001．
25．李宁，袁国伟，黎德育．化学镀镍基合金理论与技术．哈尔滨：哈尔滨工业大学出版社．2000．
26. Doss,S.K. and J.D.Michaelsen: Paper presented at Electroless Nickel Conference Ⅱ(1982).
27. Gutzeit,G: Plating,46(1959)Oct.,pp.1158～1164
28．刘汝涛，高灿柱，隋华等．化学镀镍液中镍离子浓度的快速测定．材料保护，1998，31(10)：25～27
29．徐智谋，刘宏芳等．化学镀制备功能梯度材料的实验研究．复合材料学报，2000，17(4)：66～70
30. Feldstein N, et al.J.Elextrochem.Soc..1971,118～869
31. Ldas D,Chin T. Effects of bath stabilizers on electroless nickel deposition on ferrous substrates. Plating and Surface Finishing,1996,83(8):55～61
32．刘汝涛，高灿柱，杨景和等．影响化学镀镍稳定性因素的研究．表面技术，2001，30(1)10～12
33．阳范文．复合稳定剂在Ni-P化学镀中的应用．表面技术，1998，4：33～34
34．孙克宁，张弈林等．化学镀Ni-P工艺研究．电镀与环保，1998，18(3)：18～20
35．胡三媛，关永峰，徐方超．Ni-P-SiC复合镀工艺的优化．中国农业大学学报，2002，7(4)：39～42
36．孔兆利，乔尚琪，唐守秋．高耐磨性Ni-P-SiC化学复合镀层的制取．山东科学，1996，9(2)：18～22
37．韩克平，方景礼．硫脲稳定化学镀镍的机理．电镀与精饰，1996，18(3)：11～14
38．王迎春，马壮，吕广庶等．化学镀Ni-P合金的耐磨性研究．材料工程，2000，8：25～27
39．张恒，沈献民．Ni～P/SiC耐磨性化学复合镀工艺参数优化．郑州大学学报(理学版)．2004，36(3)：5～9
40．徐滨士，马世宁，刘世参等．高速电弧喷涂粒子速度和雾化特性研究。机械工程学
报，2000，30(1)：36～40
41．刘宪军，徐滨士，马世宁等．φ2mm丝材电弧喷涂系统的工艺参数和涂层性能研究．表面工程，1997．2：28～33
42．徐滨士，梁秀兵，马世宁等．新型高速电弧喷涂枪的开发研究．中国表面工程，1998．3：16～19
43. R.Simmonds. Electric-arc Metal Spraying with Low-metaling Alloys.German Plastics.
44．黄新民，邓宗钢．热处理工艺对化学沉积Ni-P-SiC复合镀层耐磨性的影响．材料保护，1996，29(3)：11～13
45. Steffens Hans Dieter, Matthias Wewel. Recent developments in vacuum arc spraying.Dortmund: Institute of technology.
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