Study on casting simulation and wear properties of honeycomb configuration ZTAp-Fe composite

Abstract

The primary objective of this research is to develop a honeycomb configuration ZTAp-Fe composite, with varying concentrations of ZTAp (zirconia-toughened alumina particles) at 5 wt%, 10 wt%, and 15 wt%, to address wear-related issues in mining machinery components. A numerical simulation of the casting process to study the temperature field variation in composites and gravity casting was subsequently performed using 30SiMn steel liquid. A comprehensive examination of the composite's characteristics was conducted, employing XRD, SEM, EDS, three-body abrasive wear, and scratch testing. The study revealed a metallurgical bonding between the interface of 30SiMn steel and the iron matrix, characterized by a fusion zone with a width of approximately 182 μm. Furthermore, the honeycomb configuration of the preform was found to enhance heat transfer during the casting process. Both 30SiMn steel and the iron matrix exhibited a room temperature organization of α-Fe, and the micron granular precipitates in the iron matrix are (Fe, Cr)7C3. However, it was observed that when the ZTAp content reached 15 wt%, particle accumulation hindered heat transfer, which led to pore defects, resulting in poor mechanical bonding between ZTAp and the iron matrix. Compared to various three-body abrasive wear loads (50 N, 90 N, and 130 N), the wear properties initially improved with an increase in ZTAp content from 5 wt% to 15 wt% but then weakened. The presence of hard-phase ZTAp was found to play a significant role in blocking scratches, and composites with 10 wt% ZTAp content exhibited excellent wear properties.