Investigation of Fe-SiC Magnetic Abrasive Particle Size Distribution，Bonded Phase Control and Processing Capabilities AITranslate

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Basic Information:

DOI：10.13373/j.cnki.cjrm.XY23040003

Chinese Library Classification Number:TG73

Citation Information:

The reliability and durability of equipment components hinge upon their surface integrity. Any roughness on the surface of a component could precipitate uneven oxide film growth, especially under conditions of extreme temperature and pressure, which are common in the nuclear industry or in an aircraft's oil pipeline. This uneven growth can induce localized stress, engendering micro-cracks, and, in extreme cases, cause industrial safety accidents. Zirconium alloys, lauded for their low thermal neutron absorption cross-section, pressure resistance, and corrosion resistance, are commonly employed in the nuclear industry, specifically for nuclear fuel casing tubes. These zirconium tubes, in contact with nuclear fuel, must withstand an extraordinarily harsh environment characterized by high temperature and pressure, water vapor, neutron irradiation damage, and nuclear reactor-induced hydrogen absorption corrosion. Traditional machining methods like grinding and honing can exacerbate surface defects, leading to further micro-crack formation or residual tensile stress on the surface of clad zirconium tubes. Thus, it is imperative to explore advanced machining technologies for high-precision surface finishing, as they could potentially enhance the tolerance of nuclear zirconium tubes and prolong their operational lifespan under severe conditions. Magnetic abrasive finishing (MAF), an innovative surface finishing process, has gained significant attention due to its tremendous potential. This process utilizes a magnetic field to drive the magnetic abrasive particle (MAP) across the workpiece's surface, resulting in a precise, micro-level material removal. This method can alleviate surface unevenness, facilitating more efficient processing of non-standard parts and consequently augmenting the components' durability. The efficiency and precision of MAF depend critically on the MAPs. Specifically, uneven MAP particle sizes and poorly distributed hard particles pose the most significant challenges, leading to an unstable processing effect. This study employed a metal/ceramic composite theory, using Fe powder as the ferromagnetic phase and SiC particles as the hard phase, and prepared the magnetic abrasives by mechanical ball milling, sintering, and sieving. The particle size distribution of the MAPs was adjusted through crushing time. The structure, bonding phase composition, and processing performance of Fe-SiC composite MAPs prepared via the sintering method, and their different particle sizes, were explored. The processing force of the MAPs was supplied by an external magnetic field, the magnitude of which depended on both the magnetic field and the MAPs themselves. This study utilized ANSYS Maxwell 16.0 software to optimize the structure of the magnetic pole driving the MAPs. By introducing a slot at the magnetic pole's base, MAPs could rotate and refresh during the machining process, thus improving the intensity and uniformity of the magnetic field distribution on the workpiece's surface. Characteristics of MAPs were analyzed via X-ray diffraction (XRD), physical property measurement system (PPMS-VSM), scanning electron microscope (SEM), and energy dispersive analysis (EDS). These MAPs were then used in the optimized magnetic pole processing system to experimentally process nuclear zirconium alloy tube parts. The study analyzed the impacts of different MAP particle sizes on processing efficiency and accuracy, optimizing experimental parameters to achieve a tube rotation speed of 1000 r·min^-1, a working gap of 2 mm, and a feed rate of 84 mm·min^-1. The study characterized changes in roughness and surface thickness of the zirconium alloy tube parts before and after processing using a roughness measuring instrument and an optical microscope. Surface morphology was assessed via laser confocal imaging, and residual stress changes were analyzed with a residual stress analyzer.The experimental results revealed that MAPs prepared through the sintering method possessed a favorable multi-angular shape, and the particle size distribution followed a normal distribution pattern with crushing time. Furthermore, the SiC hard particles were uniformly embedded in the iron matrix, generating a stable transition bonding phase of Fe3Si. As the particle size of MAPs decreased, the relative content of Fe₃Si gradually increased. The coercivity and saturation magnetization strength of small (80 μm), medium (150 μm), and large (250 μm) MAPs were 4.59 kA·m^-1 and 137.67 Am²·kg^-1, 2.09 kA·m^-1 and 171.74 Am²·kg^-1, and 2.92 kA·m^-1 and 168.22 Am²·kg^-1, respectively. The large-sized MAPs were suitable for rapid surface material removal, while the small-sized MAPs enabled finer surface processing, offering a solution for establishing gradient processing procedures according to the distinct requirements of the surfaces being processed. Additionally, after processing nuclear industry zirconium alloy tube parts with magnetic abrasives, the final wall thickness of the processed zirconium tube was reduced by 11.37 μm, the surface residual stress changed from -145.24 to -222.29 MPa (an increase in compressive stress by 53%), and the surface roughness reduced from 0.327 to 0.117 μm.