Composite wear component

Abstract

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 Al 2 O 3 and 80 to 20% of ZrO 2 , the percentages being expressed by weights of the constituents, and the pad then being impregnated with a liquid metal during the casting.

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 Al 2 O 3  and 80 to 20% of ZrO 2 , 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  claim 1 , wherein the ceramic material includes from 55 to 60% by weight of Al 2 O 3  and from 38 to 42%   40  to  45 % by weight of ZrO 2 . 
     
     
       3. Composite wear component according to  claim 1 , wherein the ceramic material includes from 70 to 77% by weight of Al 2 O 3  and from 23 to 27   30 % by weight of ZrO 2 . 
     
     
       4. Composite wear component according to  claim 1 , wherein the content of ceramic materials in the insert is between 35 and 80% by weight  volume. 
     
     
       5. Composite wear component according to  claim 1 , wherein the inserts consist of an aggregate of composite ceramic grains which have a particle size within the range F6 to F22 according to the FEPA standard. 
     
     
       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  claim 7 , wherein the pad does not contain more than 4% of adhesive. 
     
     
       9. Composite wear component according to  claim 1  produced by casting and composed of a metal matrix including at least one ceramic pad, and  at least two ceramic pads are placed side by side  superposed, leaving a gap of the order of 10 mm in order to permit the arrival of the liquid metal. 
     
     
       10. Composite wear component produced by classical or centrifugal casting according to  claim 1  and made up of a metal matrix including a wear-resistant ceramic pad, wherein the ceramic pad is in the form of a honeycomb structure in which the various cells are of polygonal or circular shape within the ceramic phase. 
     
     
       11. Composite wear component according to  claim 10 , wherein a thickness of walls of the various cells constituting the ceramic phase varies from 5 to 25 mm. 
     
     
       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 Al   2   O   3    and  80  to  20   %  of ZrO   2   , 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.     
     
     
       13. Composite wear component according to  claim 12 , wherein the ceramic material includes from  55  to  60 %  by weight of Al   2   O   3    and from  38  to  42   %  by weight of ZrO   2   .   
     
     
       14. Composite wear component according to  claim 12 , wherein the ceramic material includes from  70  to  77 %  by weight of Al   2   O   3    and from  23  to  27   %  by weight of ZrO   2   .   
     
     
       15. Composite wear component according to  claim 12 , wherein the content of ceramic materials in the insert is between  35  and  80 %  by weight.   
     
     
       16. Composite wear component according to  claim 12 , wherein the inserts include an aggregate of composite ceramic grains which have a particle size within the range F 6  to F 22  according to the FEPA standard. 
     
     
       17. Composite wear component according to  claim 16 , wherein the ceramic grains are manufactured by one of electrofusion, sintering and flame spraying. 
     
     
       18. Composite wear component according to  claim 16 , 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. 
     
     
       19. Composite wear component according to  claim 18 , wherein the pad does not contain more than  4 %  of adhesive.   
     
     
       20. Composite wear component produced by classical or centrifugal casting according to  claim 12  and made up of a metal matrix including a wear- resistant ceramic pad, wherein the ceramic pad is in the form of a honeycomb structure in which the various cells are of polygonal or circular shape within the ceramic phase.   
     
     
       21. Composite wear component according to  claim 20 , wherein a thickness of walls of the various cells constituting the ceramic phase varies from  5  to  25  mm. 
     
     
       22. Composite wear component accordint to  claim 12  produced by casting and composed of a metal matrix including at least two ceramic pads superposed, leaving a gap of the order of  10  mm in order to permit the arrival of the liquid metal.