Preparation of new high hardness martensitic iron-based alloy powders by electrode induction gas atomization
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摘要: 利用正交试验研究了电极感应气雾化（electrode induction gas atomization，EIGA）制粉工艺参数（雾化压力、雾化气体温度和熔炼功率）对新型高硬度马氏体铁基合金粉末粒径分布、粉末流动性和收得率的影响规律。结果表明，粉末粒径分布及其特征主要取决于雾化压力，粉末流动性及收得率主要受雾化压力及雾化气体温度的影响。当制粉工艺参数为雾化压力1.5 MPa、熔炼功率15 kW、雾化气体温度40 ℃时，所得粉末的收得率最高，粒径大小在53～180 μm之间的粉末质量占比高达68.24%，兼具较好的粉末流动性及粉末粒度分布标准偏差，粉末形貌最佳。Abstract: The effects of the electrode induction gas atomization parameters (atomization pressure, gas temperature, and melting power) on the particle size distribution, powder fluidity, and yield of the new high hardness martensitic iron-based alloy powders were studied by orthogonal test. The results show that, the particle size distribution is mainly affected by the atomization pressure, while the fluidity and yield of the powders are affected by the atomization pressure and the gas temperature. When the atomization pressure is 1.5 MPa, the melting power is 15 kW, and the atomization gas temperature is 40 ℃, the powders have the largest powder yield, the mass proportion of powders with the particle size of 53~180 μm accounts for 68.24%, and the powders show the well powder fluidity, the standard deviation of powder size distribution, and the best powder morphology.
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图 2 正交试验各参数下的粉末粒径分布特征：（a）工艺1#；（b）工艺2#；（c）工艺3#；（d）工艺4#；（e）工艺5#；（f）工艺6#；（g）工艺7#；（h）工艺8#；（i）工艺9#
Figure 2. Particle size distribution characteristics under the different orthogonal test parameters: (a) process 1#; (b) process 2#; (c) process 3#; (d) process 4#; (e) process 5#; (f) process 6#; (g) process 7#; (h) process 8#; (i) process 9#
图 3 不同工艺条件制备的粉末形貌特征：（a）工艺4#；（b）工艺8#；（c）工艺3#；（d）工艺1#
Figure 3. Particle morphology of the powders prepared in the different gas atomization parameters: (a) process 4#; (b) process 8#; (c) process 3#; (d) process 1#
图 4 雾化压力对粉末性能影响的极差分析
Figure 4. Range analysis of the atomization pressure on the powder properties
图 5 熔炼功率对粉末性能影响的极差分析
Figure 5. Range analysis of the melting power on the powder properties
图 6 雾化气体温度对粉末性能影响的极差分析
Figure 6. Range analysis of the gas temperature on the powder properties
图 7 高硬度铁基合金粉末X射线衍射图谱
Figure 7. X-ray diffraction patterns of the high hardness iron-based alloy powders
图 8 高硬度铁基合金粉末粒子截面整体组织形貌：（a）和局部放大图（（b）和（c））
Figure 8. Microstructure (a) and the enlarged morphology ((b) and (c)) in the cross section of the high hardness iron-based alloy powders
表 1 高硬度马氏体铁基合金棒化学成份（质量分数）
Table 1. Chemical composition of the high hardness martensitic iron-based alloy
% C Ni Cr Si B V P S Fe 0.12～0.20 1.5～2.8 16～17 0.5～1.0 0.4～1.0 0.1～0.3 ≤0.03 ≤0.03 余量 
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表 2 气雾化工艺正交实验表L9（3×3）
Table 2. Orthogonal test of the gas atomization parameters L9 (3×3)
工艺 F / MPa P / kW T / ℃ 1# 1.0 15 20 2# 1.0 20 40 3# 1.0 25 60 4# 1.5 15 40 5# 1.5 20 60 6# 1.5 25 20 7# 2.0 15 60 8# 2.0 20 20 9# 2.0 25 40
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表 3 粉末粒径分布特征值、流速及粉末收得率
Table 3. Characteristic values of the particle size distribution, flow rate, and yield of powders
工艺 D50 / μm D84.13 / μm δ S / [s·(50 g)−1] w / % 1# 99.80±0.31 166.00±0.32 1.67 12.75±0.21 58.41±0.38 2# 101.00±0.40 165.00±0.35 1.63 12.94±0.13 65.32±0.32 3# 99.30±0.37 164.00±0.31 1.65 12.82±0.21 52.58±0.35 4# 91.90±0.45 161.00±0.24 1.75 13.40±0.24 68.24±0.40 5# 93.00±0.30 159.00±0.29 1.71 13.20±0.19 56.94±0.22 6# 91.70±0.28 159.00±0.21 1.73 12.75±0.18 65.41±0.27 7# 87.70±0.21 142.00±0.22 1.62 13.66±0.22 55.13±0.29 8# 88.10±0.24 142.00±0.19 1.61 13.00±0.23 50.38±0.23 9# 87.00±0.37 149.00±0.25 1.71 14.10±0.12 50.12±0.29
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表 4 各影响因素显著性分析结果
Table 4. Significance analysis based on the various factors
粉末性能 F / MPa P / kW T / ℃ D50 12.43 1.36 0.13 δ 0.10 0.05 0.04 S 0.75 0.22 0.65 w 12.65 4.55 6.35
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表 5 制备的高硬度铁基合金粉末化学成份（质量分数）
Table 5. Chemical composition of the high hardness iron-based alloys
% C Ni Cr Si B V P S Fe 0.12 2.46 16.87 0.77 0.64 0.22 0.019 0.0032 余量
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