Background
The invention mainly solves the problems of corrosion and abrasion of a valve seat of a methanol direct injection fuel injector in a high-temperature methanol environment and cavitation on the surface of the valve seat in a high-pressure gradient methanol fluid environment, and provides an anti-cavitation scheme for solving the problem that an ion sputtering process is applied to a microporous structural member. A plurality of cases of abrasion of the valve seat of the direct injection fuel injector occur in the verification test process, and carbon elements on the surface of the valve seat are separated out under the high-temperature methanol environment through failure mode analysis, so that the surface is accelerated to be abraded, the sealing function of the valve seat is invalid, and the fuel injector drips and leaks methanol. Therefore, the methanol direct injection fuel injector needs to adopt low-carbon stainless steel and adopts a coating technology to improve the surface wear resistance and corrosion resistance.
The valve seat coatings disclosed in the prior art, such as valve seat DLC coatings, are metastable amorphous materials that combine to form sp3 and sp2 bonds. Because the base material of the low-carbon acid-resistant stainless steel valve seat is softer, the sealing surface of the base material can slightly deform when the oil sprayer works, the deformation can cause the internal stress of the DLC coating to be increased, and finally sp3 and sp2 bond fracture failure is caused. Thus, currently, valve seats of conventional materials and DLC processes are not suitable for methanol direct injection injector valve seats.
The valve seat material needs to have higher hardness and wear resistance, so the valve seat material needs to be made of stainless steel with carbon content of more than 0.2 percent. Meanwhile, the valve seat material needs stronger corrosion resistance, including high-temperature methanol resistance and corrosion of methanoic acid and derivatives generated by methanol in a high-temperature methanol environment. Stainless steel with good high temperature methanol and formic acid corrosion resistance is generally low carbon alloy stainless steel with carbon content below 0.1%. And the corrosion-resistant stainless steel with carbon content below 0.1% has low hardness and cannot meet the wear resistance requirement of the valve seat. The two performance requirements are in technical conflict with the need for carbon content.
Disclosure of Invention
The invention discloses a metal part which is used for meeting the requirements of low-carbon steel on high-temperature methanol and formic acid corrosion resistance and high hardness and relieving the technical contradiction of carbon content requirements.
In order to achieve the above purpose, the present invention provides the following technical solutions:
A metal part includes a metal base body that is low-carbon stainless steel and has a contact surface formed with a nitriding layer. Nitriding the contact surface can improve cavitation resistance of the contact surface of the metal matrix, particularly cavitation resistance of the inner surface of the micropore, can improve hardness of the contact surface of the low-carbon stainless steel metal matrix, and has better hardness when the low-carbon stainless steel is adopted to resist high-temperature methanol and formic acid corrosion. The surface of the nitriding layer is provided with a silicon coating, and the risk that trace carbon in the contact surface of the low-carbon stainless steel is precipitated in a carbon compound form is further reduced by utilizing the acid corrosion resistance characteristic of the silicon coating, so that the corrosion resistance of the contact surface of the metal substrate is secondarily strengthened.
Optionally, the nitrided layer has a thickness between 2 μm and 20 μm.
Optionally, the metal matrix is low-carbon stainless steel with carbon content below 0.1%.
Optionally, a silicon coating is formed on the surface of the nitriding layer.
Optionally, the thickness of the silicon coating is between 0.1 μm and 0.5 μm.
Optionally, a chromium nitride coating is formed on the surface of the silicon coating facing away from the nitriding layer.
Optionally, the chromium nitride coating has a chromium nitride content of greater than 80%, and the chromium nitride coating has a thickness of between 0.6 μm and 1 μm.
Optionally, a sealing functional layer is formed on the surface of the chromium nitride coating, which faces away from the silicon coating, the hardness of the sealing functional layer is lower than that of the chromium nitride coating, and the corrosion resistance of the sealing functional layer is higher than that of the chromium nitride coating.
Optionally, the sealing functional layer is a chromium coating.
Optionally, the thickness of the chromium coating is between 0.3 μm and 0.7 μm.
Optionally, a gradual transition layer is arranged between the chromium coating and the chromium nitride coating, and in the gradual transition layer, along the direction from the chromium nitride coating to the chromium coating, the content of chromium nitride is gradually reduced, and the content of chromium is gradually increased.
Optionally, the metal substrate is a valve seat of the direct methanol injection fuel injector, and the contact surface is a contact sealing surface between the valve seat and the valve core.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the metal part provided by the embodiment of the application can adapt to a high-temperature methanol corrosion environment, can be a kinematic pair part which is applied to various purposes and is contacted with high-temperature methanol, and comprises a metal substrate 1, wherein the metal substrate 1 is low-carbon stainless steel, for example, low-carbon stainless steel with carbon content of less than 0.1%, the type of stainless steel has good high-temperature methanol and formic acid corrosion resistance, and is provided with a contact surface S, and a nitriding layer 2 is formed on the contact surface S. Nitriding the contact surface S can improve cavitation resistance of the contact surface S of the metal matrix 1, particularly cavitation resistance of the inner surface of the micropore, can improve hardness of the contact surface S of the low-carbon stainless steel metal substrate, and can have better hardness when adopting low-carbon stainless steel to resist high-temperature methanol and formic acid corrosion. The surface of the nitriding layer 2 is provided with a silicon coating 3, and the risk that trace carbon on the contact surface S of the low-carbon stainless steel is precipitated in the form of a carbon compound is further reduced by utilizing the acid corrosion resistance characteristic of the silicon coating 3, so that the corrosion resistance of the contact surface S of the metal substrate 1 is secondarily strengthened. The silicon coating 3 may be a siliconizing layer formed by a siliconizing process as a high temperature methanol corrosion resistant layer to prevent corrosion of the metal substrate 1 by high temperature methanol. Specifically, the silicon coating 3 may be formed using an ion sputtering process.
The contact surface S refers to a surface that contacts methanol or a high-temperature methanol environment and carries an impact load or a friction load, and may be a sealing contact surface of a valve seat and a valve ball of a valve element.
In a specific embodiment, the nitriding layer 2 has a thickness of between 2 μm and 20 μm, specifically 2 μm, 4 μm, 6 μm, 7 μm, 9 μm, 12 μm, 14 μm, 15 μm, 17 μm, 19 μm, 20 μm, etc., within which the cavitation resistance of the microporous inner surface can be sufficiently improved while the surface hardness of the metal base 1 is improved and while the nitriding cost is limited to a reasonable range.
In a specific embodiment, the thickness of the silicon coating 3 is between 0.1 μm and 0.5 μm, and may be specifically 0.1 μm, 0.2 μm, 0.3 μm, 0.4 μm, 0.5 μm, etc. When the thickness of the silicon coating layer 3 is within this range, the carbon precipitation as a carbon compound can be sufficiently reduced, and the corrosion resistance can be sufficiently achieved while achieving reasonable cost.
In a specific embodiment, the surface of the silicon coating 3 facing away from the nitrided layer 2 is formed with a chromium nitride coating 4. The chromium nitride coating 4 can simultaneously improve the wear resistance and corrosion resistance of the contact surface S of the metal substrate 1 subjected to impact load. The chromium nitride coating 4 may be a chromium nitride layer formed by a chromium nitride process, which has a higher hardness and better impact resistance than the silicon coating 3.
In a specific embodiment, the chromium nitride content in the chromium nitride coating 4 is greater than 80%, and the thickness of the chromium nitride coating 4 is between 0.6 μm and 1 μm, which may be specifically 0.6 μm, 0.7 μm, 0.8 μm, 0.9 μm, 1 μm, etc. When the thickness of the chromium nitride coating 4 is within this range, it is possible to maintain the wear resistance of the contact surface S and the corrosion resistance of the contact surface S while giving a reasonable cost.
In a specific embodiment, the surface of the chromium nitride coating 4 facing away from the silicon coating 3 is formed with a sealing functional layer 5, and the hardness of the sealing functional layer 5 is lower than that of the chromium nitride coating 4, so that the running-in speed between the contact surface S and the matched surface can be increased, for example, the running-in speed of the valve seat, the valve core and the valve ball is increased, the sealing surface is rapidly formed at the initial stage of the operation of the fuel injector, and the corrosion resistance of the sealing functional layer 5 is higher than that of the chromium nitride coating 4, so as to further improve the corrosion resistance.
In a specific embodiment, the sealing functional layer 5 is a chromium coating, the hardness of the chromium coating is lower than that of the chromium nitride coating 4, and the corrosion resistance is higher than that of the chromium nitride coating 4, so that the sealing functional layer 5 can be used as a material of ideal sealing functional layer 5. The thickness of the chromium coating may be between 0.3 μm and 0.7 μm, and may specifically be 0.3 μm, 0.4 μm, 0.5 μm, 0.6 μm, 0.7 μm, etc. The thickness range can simultaneously give consideration to hardness, corrosion resistance and reasonable cost.
In a specific embodiment, a gradual transition layer is arranged between the chromium coating and the chromium nitride coating 4, in the gradual transition layer, along the direction from the chromium nitride coating 4 to the chromium coating, the content of chromium nitride is gradually reduced, and the content of chromium is gradually increased so as to gradually evolve towards the components of the chromium coating, and the situation that the components cannot be well combined due to overlarge component difference between the chromium coating and the chromium nitride coating is avoided.
Referring to fig. 2 to 4, a conical surface on the injector valve seat a contacts with the ball of the valve core b to form a contact sealing surface. The ball head of the valve core b and the conical sealing surface of the valve seat a form a kinematic pair which is subjected to impact load. In a specific embodiment, the metal substrate 1 is a valve seat a of a direct methanol injection fuel injector, and the contact surface S is a contact sealing surface of the valve seat a and the valve core b. The valve seat a is arranged at the oil outlet end of the valve body c, the valve core b is arranged in the space of the valve body c, and the valve ball at the end part is in sealing fit with the contact sealing surface of the valve seat a. By surface-treating the contact surface S of the valve seat a, the hardness of the contact sealing surface of the valve seat a and the valve body b can be increased, and carbon precipitation of the valve seat a can be prevented by using low-carbon stainless steel.
It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments of the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention also include such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.