CN102459124A - 基于氧化铝和氧化锆的烧结制品 - Google Patents
基于氧化铝和氧化锆的烧结制品 Download PDFInfo
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- CN102459124A CN102459124A CN2010800249669A CN201080024966A CN102459124A CN 102459124 A CN102459124 A CN 102459124A CN 2010800249669 A CN2010800249669 A CN 2010800249669A CN 201080024966 A CN201080024966 A CN 201080024966A CN 102459124 A CN102459124 A CN 102459124A
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Abstract
本发明涉及一种烧结颗粒,所述烧结颗粒具有以重量百分比计的以下化学分析:用CeO2和Y2O3部分稳定化的ZrO2:至100%的余量;Al2O3:10%-60%;选自CaO、锰的氧化物、La2O3、SrO、BaO和它们的混合物的添加剂:0.2%-6%;CaO,其量小于:2%;杂质:<2%;所述氧化锆被满足以下条件的量的CeO2和Y2O3稳定化,按基于ZrO2、CeO2和Y2O3的和的摩尔百分比计:CeO2:6-11mol%;以及Y2O3:0.5-2mol%,所述颗粒是通过在高于1300℃的烧结温度下烧结而获得的,如果所述添加剂是CaO或如果CeO2的摩尔含量在10%到11%的范围中,所述烧结温度高于1400℃。
Description
技术领域
本发明涉及一种基于氧化铝和氧化锆的烧结制品以及它们在研磨机中的用途,所述烧结制品尤其为烧结珠。
背景技术
术语“耐火制品”包括熔铸制品和烧结制品。
与烧结制品对比,熔铸制品通常包括非常结实的晶间玻璃相,所述晶间玻璃相遍及大量结晶颗粒。因此,烧结制品和熔铸制品在它们各自的应用中所遇到的问题以及为解决所述问题而采用的技术方法通常是不同的。而且,由于它们的制造方法之间差异很大,为制造熔铸制品而研制的组分本身先天地不能够用来制造烧结制品,反之亦然。
通过以下步骤获得烧结制品:将适当的原始材料混合,接着将未经烧制的混合物塑形并在一温度下烧制所产生的坯体足够时间以烧结所述坯体。
取决于它们的化学组成,烧结制品具有各种性质且因此用于各种行业。
一个非常专门的应用是通常以珠的形式的烧结制品用作研磨介质,尤其用来细磨矿物物质、无机物质或有机物质。在该应用中,所述珠被分散在温度可超过80℃的水介质或溶剂中,接着通过接触待研磨的物质、通过相互接触且通过与研磨机的元件接触,所述珠经受摩擦。因此,所述珠的使用寿命直接取决于它们在该水介质或溶剂中的耐磨性。
US2009/0036291(或WO2009/018024)公开了基于氧化锆和氧化铝的烧结珠,所述烧结珠包括大致9%到12%的二氧化铈CeO2和范围在0.01%到0.8%的氧化钙CaO。所述公开将所述的烧结珠与CeO2-TZP(“以CeO2-稳定的四方氧化锆多晶体”)珠作比较,但基于历史数据认为无需将其与Y-TZP珠进行比较,Y-TZP因其在水介质中性能差而众所周知。
改进烧结珠的组分,尤其通过加入新的氧化物即使加入很少量,对其性质可以有很大的影响。还已知氧化锆的稳定相的量可以通过热处理或机械处理该氧化锆而改变。
为了提高研磨操作的产率,需要研磨颗粒更耐磨同时在热流体介质中具有高抗降解性,尤其是它们与高于80℃的水接触时;下文中,这样的条件被称为“水热条件”。
而且,朝着提高研磨产率即在给定成本下获得最大量的研磨材料而不断努力。
本发明的目的是至少部分地满足这些需求。
发明内容
本发明提出了一种具有以下化学分析的烧结颗粒,按重量百分比计:
·用CeO2和Y2O3部分稳定的ZrO2:至100%的余量;
·Al2O3:10%-60%;
·选自CaO、锰的氧化物、ZnO、La2O3、镨的氧化物、SrO、铜的氧化物、Nd2O3、BaO、铁的氧化物和它们的混合物的添加剂:0.2%-6%;
·CaO,其量小于:2%;
·杂质:<2%;
CeO2和Y2O3,其量按基于ZrO2、CeO2和Y2O3的和的摩尔百分比计,使得:
·CeO2:6-11mol%;以及
·Y2O3:0.5-2mol%;
所述颗粒是通过在高于1300℃的烧结温度下烧结而获得的,所述烧结温度高于1400℃、优选地高于1425℃:
(C1)如果添加剂是CaO;或
(C2)如果CeO2的摩尔含量在10%到11%的范围中。
在以下描述中可以更详细地看到,这样的烧结颗粒具有优秀的耐磨性,即使是在水热条件下。
而且,所述颗粒的密度相对低。由于可以装入研磨机的颗粒的重量通常构成限制性因素,本发明的烧结颗粒的密度意味着:有利地,可以装入大量所述颗粒。
而且,所述颗粒已降低了氧化锆和CeO2的含量。由于氧化锆和褐帘石是昂贵的材料,因此对于给定的资金,可能产生较多的烧结颗粒并将大量烧结颗粒添加入研磨机中。因此,本发明的烧结颗粒可以用来获得很高的研磨产率。
概括来讲,本发明的烧结颗粒意味着可以在水热条件下的耐磨性和研磨产率之间获得非常好的折中。
本发明的烧结颗粒还可具有以下选择性特性的一个或多个特性:
-按基于ZrO2、CeO2和Y2O3的和的摩尔百分比计,CeO2的所述摩尔量小于10.0%、优选地小于9.5%和/或优选地大于7.0%、优选地大于7.5%、优选地大于8.0%甚或大于8.5%;
-按基于ZrO2、CeO2和Y2O3的和的摩尔百分比计,Y2O3的所述摩尔量小于1.9%、小于1.7%、小于1.5%、小于1.2%和/或大于0.7%、甚或大于0.8%;
-在特定的实施方式中,按基于ZrO2、CeO2和Y2O3的和的摩尔百分比计,CeO2的所述摩尔量在8.5%到9.5%的范围中,Y2O3的所述摩尔量在0.8%到1.2%的范围中;
-按基于氧化物的重量百分比计,氧化铝Al2O3的量大于15%、甚或大于20%和/或小于55%、甚或小于50%、甚或小于40%、甚或小于35%;
-所述锰的氧化物选自MnO、MnO2、Mn2O3、Mn3O4和它们的混合物。优选地,所述锰的氧化物选自MnO、Mn3O4和它们的混合物;
-所述镨的氧化物是Pr6O11;
-所述铜的氧化物是CuO;
-所述铁的氧化物选自FeO、Fe2O3和它们的混合物;
-所述添加剂选自CaO、MnO、MnO2、Mn2O3、Mn3O4、ZnO、La2O3、SrO和它们的混合物;
-所述添加剂选择CaO、锰的氧化物、La2O3、SrO、BaO和它们的混合物,优选地选自CaO、MnO、MnO2、Mn2O3、Mn3O4和它们的混合物;
-优选地,所述添加剂选择CaO、MnO、Mn3O4和它们的混合物。更优选地,所述添加剂是CaO与MnO和/或Mn3O4的混合物。优选地,所述添加剂选自CaO、MnO和它们的混合物。更优选地,所述添加剂是CaO和MnO的混合物。
-按基于氧化物的重量百分比计,添加剂的量大于0.3%、大于0.4%、甚或大于0.5%或大于0.6%和/或小于5%、甚或小于4%、甚或小于3%、甚或小于2.5%、甚或小于2%、甚或小于1.5%、甚或小于1%;
-所述添加剂包括CaO,按基于氧化物的重量百分比计,CaO的量大于0.3%、甚或大于0.4%、大于0.5%和/或小于1.5%、优选地小于1%、甚或小于0.8%、甚或小于0.6%;
-所述添加剂包括CaO和选自MnO、MnO2、Mn2O3、Mn3O4、ZnO、La2O3、SrO和它们的混合物、尤其是MnO和Mn3O4的混合物的第二添加剂物质,按基于氧化物的重量百分比计,所述第二添加剂物质的量优选地大于0.1%、大于0.2%和/或小于4.0%、优选地小于3.5%、甚或小于3.0%、甚或小于2.5%、甚或小于2.0%、甚或小于1.5%、甚或小于1.0%、甚或小于0.8%、甚或小于0.6%、甚或小于0.5%、甚或小于0.4%、甚或小于0.3%;
-按基于氧化物的重量百分比计,La2O3的量小于5.2%、小于5.0%、甚或小于4.5%;
-按基于氧化物的重量百分比计,杂质的量小于1.0%、优选地小于0.8%、优选地小于0.5%、甚或小于0.3%。在一个实施方式中,所述杂质由氧化物构成;
-优选地,按基于氧化物的重量百分比计,二氧化硅SiO2的量小于1.5%、小于1.0%、优选地小于0.7%、优选地小于0.5%;
-所述颗粒是通过在1320℃或更高、高于1400℃、高于1425℃和/或低于1550℃的温度下烧结而获得的。具体地,可以通过以下所述的根据本发明的方法获得所述颗粒;
-优选地,根据本发明的烧结颗粒的部分稳定的氧化锆粒子和氧化铝粒子的组的平均粒度小于3μm[微米]、优选地小于2.5μm、甚或小于2μm、甚或小于1.5μm、甚或小于1μm、甚或小于0.8μm且优选地大于0.1μm;
-所述烧结颗粒以珠的形式,优选地以圆球度大于0.7的珠的形式;
-所述烧结颗粒具有细长形状的粒子;
-按数量计,具有细长形状的所述粒子的大于80%、大于90%甚或基本上100%具有大体矩形的形状;
-利用X-射线衍射测得,具有细长形状的粒子的数目优选地大于0.05%、优选地大于0.10%、优选地大于0.15%、优选地大于0.20%、优选地大于0.25%、优选地大于0.3%、甚或大于0.4%和/或小于5%、甚或小于3%、优选地小于2%、优选地小于1%。具有细长形状的粒子的数目的测量在本发明的剩余部分中详述;
-具有细长形状的所述粒子包括元素Al和作为添加剂添加的氧化物的金属阳离子(Ca和/或Mn和/或Zn和/或La和/或Pr和/或Sr和/或Cu和/或Nd和/或Ba和/或Fe)。具有细长形状的所述粒子还可包括元素铈(Ce)。因此,如果该添加剂包括CaO和MnO,具有细长形状的所述粒子包括元素Al、Ca、Mn和Ce。所述烧结颗粒的密度大于4.8g/cm3[克每立方厘米]、甚或大于4.9g/cm3和/或小于5.5g/cm3、甚或小于5.3g/cm3。
-所述烧结颗粒是利用不包括热等静压(HIP)步骤的方法制造的;
-所述烧结颗粒是利用包括滴铸(drip casting)步骤的方法制造的;
-本发明还提供了这样一组颗粒:按重量百分比计,其包括大于90%、优选地大于95%、优选地大致100%的本发明的烧结颗粒。
本发明还提供了一种制造根据本发明的烧结颗粒、尤其是烧结珠的方法,所述方法包括以下连续步骤:
a)必要的话,研磨一种或多种原材料粉末,优选地通过共研磨来进行研磨,以通过使得所述粉末混合来获得粒度中值小于1.0μm的颗粒混合物;
b)自所述粉末制备悬浮液,调整所述悬浮液的组分以便在步骤f)结束时获得组分与根据本发明的烧结颗粒的组分一致的烧结颗粒;
c)使所述悬浮液的微滴硬化成未经烧制的颗粒;
d)洗涤;
e)干燥;
f)在大于1300℃的烧结温度下进行烧结以获得烧结颗粒;
所述烧结温度大于1400℃、优选地大于1425℃:
(C’1)如果所述悬浮液不包括Mn、Zn、Cu、Pr、Nd、Sr、La、Ba、或Fe的化合物,即如果所述烧结颗粒中的添加剂是CaO;
(C’2)或者如果所述悬浮液使得,按基于ZrO2、CeO2和Y2O3的和的摩尔百分比计,步骤f)结束时获得的烧结颗粒的CeO2的摩尔含量在10%到11%的范围中。
根据本发明的方法还可包括以下选择性特性中的一个或多个特性:
-执行用于研磨原材料的一种或多种粉末的步骤a),优选地通过共研磨来进行研磨,以通过混合所述粉末来获得平均粒度小于0.6μm、优选地小于0.5μm、优选地小于0.3μm、优选地小于0.2μm的颗粒混合物;
-所述方法至少在烧结步骤结束之前不包括等静压步骤,尤其是热等静压(HIP)步骤;
-所述烧结温度低于1550℃;
-所述烧结温度为1320℃或更高、或者高于1400℃或高于1425℃。
本发明还提供了本发明的烧结颗粒或者利用根据本发明的方法制造或能够利用根据本发明的方法制造的颗粒作为研磨介质的用途,尤其用于微研磨。本发明还提供了包括根据本发明的烧结颗粒的研磨机。
本发明还提供了包括以下颗粒的颗粒混合物:颗粒ZrO2、Al2O3、CeO2和Y2O3以及选择性地颗粒CaO和/或锰的氧化物和/或ZnO和/或La2O3和/或镨的氧化物和/或SrO和/或铜的氧化物和/或Nd2O3和/或BaO和/或铁的氧化物和/或所述氧化物的前体颗粒,它们成比例使得通过烧结所述颗粒混合物,可以获得根据本发明的烧结颗粒。
有利地,这样的颗粒混合物准备开始使用。尤其是,其可以用在用于产生悬浮液的步骤b)中。
根据本发明的颗粒混合物尤其可以装进袋子。
优选地,所述颗粒混合物的粒度中值小于1μm、优选地小于0.6μm、优选地小于0.5μm、优选地小于0.3μm甚或小于0.2μm。
定义:
-术语“颗粒”表示单块粉末状的固体制品;
-术语“烧结”用来描述通过在大于1100℃下热处理而固结颗粒团块,可能使其某成分(但不是其全部成分)部分或全部熔化;
-术语“珠”表示球形的颗粒(即其最小直径和其最大直径的比率大于0.6),而与获得所述球形的方式无关;
-一组颗粒的“粒度中值”(通常表示为D50)是将所述组的颗粒分成等质量的第一部分和第二部分的尺寸,所述第一部分和所述第二部分分别仅包括尺寸大于或小于所述粒度中值的颗粒。可以利用例如激光粒度计来测量所述粒度中值。
-烧结颗粒的粒子的“平均粒度”是利用“平均线性截距”方法测量的尺寸。ASTM E1382方法中描述了该类型的测量方法,还应用了作为粒度分布的函数的校正系数;
-术语“锰的氧化物”表示锰的一种或多种氧化物。具体地,可以涉及MnO、Mn2O3、MnO2和Mn3O4;
-术语“铁的氧化物”表示铁的一种或多种氧化物。具体地可以涉及FeO、Fe2O3知Fe3O4;
-术语“镨的氧化物”表示镨的一种或多种氧化物。具体地可以涉及Pr2O3;
-术语“铜的氧化物”表示铜的一种或多种氧化物。具体地可以涉及CuO、Cu2O;
-术语“杂质”表示必然地与原始材料一起添入的不可避免的成分。具体地,属于金属钠以及其他碱金属、钒和铬以及它们的氧化物、氮化物、氮氧化物、碳化物、碳氧化物、碳氮化物的化合物是杂质。可以涉及以下示例:Na2O或MgO。反之,氧化铪不看作是杂质;
-HfO2不能与ZrO2化学分离。因此,在包括氧化锆的制品的化学组分中,“ZrO2”表示这两种氧化物的总量。然而,在本发明中,并不故意地将HfO2添加至所述原材料中。因此,“HfO2”仅表示痕量的氧化铪,因为该氧化物总是以通常小于2%的量自然存在于氧化锆的源中。为了清楚,则氧化锆和痕量的氧化铪的量可以可互换地表示为“ZrO2+HfO2”或“ZrO2”或“氧化锆含量”;
-术语氧化物的“前体“表示能够在制造根据本发明的烧结颗粒期间提供所述氧化物的成分。作为示例,碳酸钡BaCO3是BaO的可能的前体;
-术语粒子的“形状因数”(表示为“F”)用于所述粒子的最大尺寸“Ga”与垂直于所述尺寸Ga的方向测量的表示为“Pa”的最大尺寸的比率的倒数:F=Pa/Ga。这些尺寸通常是利用所述烧结颗粒的抛光面的摄影图像(见图1)在所述面的观察平面中测量的;
-术语“具有细长形状的粒子”表示形状因数F小于0.4的粒子;
-发明人已证明,本发明的制品根据添加剂包括黑铝钙石类型的相和/或铁磁铅矿类型的相,这些相基本上仅存在于具有细长形状的粒子中。因此,这样的相的量的测量可以用来估计具有细长形状的粒子的数目。因此“具有细长形状的粒子的数目”利用以下的公式(1)限定,表示为a%:
其中:
○A细长粒子是在X射线衍射图上测量的以下面积的和:
.对应于黑铝钙石类型的相的<110>反射的峰(第38-0470号ICDD文件);以及
.对应于磁铁铅矿类型的相的<107>反射的峰(第04-0704号ICDD文件);
○是在同一图上测量的与ZrO2的四方晶相的<111>反射对应的峰的面积(第17-0923号ICDD文件),该面积是在26.5°到31.3°范围中的2θ角域中测量的,理论上以30.19°的2θ角度为中心;
面积A细长粒子、和的测量是在利用来自供应商PANalytical的配备有铜制的X射线衍射管的X’pert型衍射仪获得的同一X-射线衍射图上进行的。在24.5°到26.5°以及31.5°到33.6°的2θ角度范围中将步长调整至0.008°和600s/步,在26.5°到31.3°的2θ角度范围中将步长调整至0.033°和300s/步。利用来自供应商BRUKER的TOPAS软件利用pseudo-voigt函数来对以每秒次数表示的峰的幅值进行去卷积处理。
术语“对应于黑铝钙石类型的相的<110>反射的峰”与“对应于磁铁铅矿类型的相的<107>反射的峰”用来表示分别在31.19°到33.19°的范围中和31.29°到33.29°的范围中的2θ角度范围中的最高峰。这些范围以2θ角度32.19°和32.29°为中心,31.29°和32.29°分别对应于纯黑铝钙石相的峰(第38-0470号ICDD文件)和对应于纯磁铁铅矿相的峰(第04-0704号ICDD文件)。相对于所述角度2θ的这些值的偏移与所使用的添加剂的性质相关。添加剂的性质还确定对应于黑铝矿石类型的相的<110>反射的峰和对应于磁铁铅矿类型的相的<107>反射的峰的存在。
除非另有说明,与制品的组分有关的或与原料有关的所有百分比是基于氧化物的重量百分比,CeO2和Y2O3的所有百分比是基于ZrO2、CeO2和Y2O3的和的摩尔百分比。
附图说明
根据以下详细描述和附图,本发明的其他特性和优势更明显,其中:
图1是根据本发明的来自示例2的烧结颗粒的抛光片的照片,所述烧结颗粒是在温度1375℃下烧结之后获得的,该颗粒在1275℃下经受30分钟热处理以在抛光之后呈现晶界。
具体实施方式
为了制造本发明的烧结颗粒,可以执行上文描述并在下文详述的步骤a)到f)。
优选地,所使用的粉末和粉状添加剂中的每个的粒度中值小于5μm、甚或小于3μm、小于1μm、小于0.7μm、优选地小于0.6μm、优选地小于0.5μm、优选地小于0.3μm甚或小于0.2μm,所述的所使用的粉末具体是ZrO2、氧化铝(Al2O3)、Y2O3、CeO2粉末。
有利地,当这些粉末中的每个的粒度中值小于1μm、优选地小于0.6μm、优选地小于0.5μm、优选地小于0.3μm甚或小于0.2μm时,步骤a)是可选择的。
利用低粒度中值的粉末也有利地意味着可以降低烧结温度。
优选地,所使用的氧化锆粉末具有大于5m2/g[平方米每克]、优选地大于8m2/g、优选地大于10m2/g并且小于30m2/g的比表面积,所述比表面积是利用BET方法测量的。有利地,降低了步骤f)中的烧结温度,因此有助于步骤a)的通常在悬浮液中的研磨以及步骤b)中的制成悬浮液。
在步骤a)中,如果原材料粉末不具有所需的粒度分布,具体地如果它们的粒度中值大于1μm、大于0.6μm、大于0.5μm、大于0.3μm或大于0.2μm,则可以单独地研磨所述原材料粉末,或者优选地,可以共研磨所述原材料粉末。
在步骤b)中,在室温下制备基于水或称为“增滑剂(slip)”的溶剂的悬浮液,其包括粉末ZrO2、Al2O3、CeO2和Y2O3以及适当的话CaO和/或锰的氧化物和/或ZnO和/或La2O3和/或镨的氧化物和/或SrO和/或铜的氧化物和/或Nd2O3和/或BaO和/或铁的氧化物中的一种或多种粉末。
这些粉末还可至少部分地由以等量添加的用于所述氧化物的前体粉末替换。
发明人已发现添加CaO和/或锰的氧化物和/或ZnO和/或La2O3和/或镨的氧化物和/或SrO和/或铜的氧化物和/或Nd2O3和/或BaO和/或铁的氧化物和/或所述氧化物的前体意味着包括在所述烧结颗粒中的具有细长形状的粒子的量可以提高并且可以提高机械性能。
发明人还发现添加锰的氧化物和/或ZnO和/或La2O3和/或镨的氧化物和/或SrO和/或铜的氧化物和/或Nd2O3和/或BaO和/或铁的氧化物和/或所述氧化物的前体意味着:如果根据本发明的烧结颗粒中的CeO2的摩尔量在7%到10%的范围中,可以将烧结温度降低至低于1400℃、低于1350℃甚或降至1300℃。
优选地,选择提供氧化物或前体的粉末使得按基于氧化物的重量百分比计,杂质的总量小于2%。
在特定的实施方式中,以利用氧化钇至少部分地稳定的氧化锆的形式添加Y2O3。
相反,且优选地,以利用氧化铈部分地稳定的氧化锆的形式仅部分添加或不添加CeO2。
增滑剂优选地具有按重量计50%到70%的干燥物质含量。
本领域的专业技术人员公知,该悬浮液还可包括以下成分:
-按基于干燥物质的重量百分比计,量为0到10%的分散剂;
-按基于干燥物质的重量百分比计,量为0到3%的粘度稳定剂或反絮凝剂;
-按基于干燥物质的重量百分比计,量为0到3%的表面张力调整剂;以及
-按基于干燥物质的重量百分比计,量为0到2%的胶凝剂。
分散剂或反絮凝剂、表面张力调整剂和胶凝剂对于本领域的专业技术人员而言是公知的。这也适用于适合于与给定的胶凝剂发生反应的电解质。
可以提到以下的示例:
-作为分散剂或反絮凝剂的聚甲基丙烯酸钠或聚甲基丙烯铵族、聚丙烯酸钠或聚丙烯酸铵族、聚丙烯酸族(铵盐或钠盐)或其他的聚合电解质、柠檬酸盐族(例如柠檬酸铵)、磷酸钠族以及碳酸酯族;
-作为表面张力调整剂的有机溶剂,比如某些脂肪醇;以及
-天然多糖族的某些成员作为胶凝剂。
所有这些成分在后续制造步骤期间消失,或仅存在痕量。
优选地,将前体和/或氧化物粉末添加至球研磨机中的水与分散剂/反絮凝剂的混合物中。在搅拌后,添加其中溶解有胶凝剂的水以获得悬浮液。
在步骤c)中,接着通过允许所述悬浮液流过校准孔口来获得所述悬浮液的液滴。离开所述孔口的液滴进入胶凝溶液的浴(与所述胶凝剂反应的电解质),在该浴中,所述液滴在获得基本上球形的形状后变硬。
在步骤d)中,将所获得的未经烧制的颗粒自所述浴移除,利用水洗涤,接着在步骤e)中烘干。
在步骤f)中,已经洗涤和被烘干的未经烧制的颗粒被烧结。可以在还原、中性或氧化环境下进行烧结。优选地,在空气、电炉中、在大气压下进行烧结。
优选地,烧结时间段大于1h[小时]、大于2h和/或小于10h、小于7h、或小于5h。优选地,所述烧结时间段在2h到5h的范围中。
步骤f)中的烧结是在高于1300℃以及优选地低于1550℃的温度下进行的。
如果所述悬浮液不包括Mn、Zn、Cu、Pr、Nd、Sr、La、Ba或Fe的化合物,即如果所述烧结颗粒中的添加剂是CaO,则烧结温度高于1400℃、优选地高于1425℃。
如果悬浮液使得在步骤f)结束时获得的烧结颗粒的CeO2的摩尔量在10%到11%的范围中,所述烧结温度高于1400℃。
当氧化铝的量增多时,烧结温度优选地更高。
所获得的烧结颗粒优选地以具有0.4mm(毫米)到10mm的范围中的最小直径的珠的形状。
出人意料地,发明人已发现本发明的烧结颗粒中存在特定的微结构。如从图1中可以看到,所述烧结颗粒包括部分稳定的氧化锆粒子1、氧化铝粒子2、具有细长形状的粒子3和孔4,所述细长形状的粒子可以具有基本上为直线杆的形状。
具有细长形状的粒子的形状因数F可以小于0.3、甚或小于0.25。
图1示出了,基本上没有具有介于具有细长形状的粒子3和具有基本上圆形形状的其他粒子之间的形状的粒子。在根据这些粒子的形状因数表示所述粒子的数目的曲线上,所述粒子被收集成形状因数组,每一组具有幅度0.05;因此有幅度大于0.1、甚或大于0.2、甚或大于0.3的一形状因数范围,该范围几乎未展示,该范围将与具有细长形状的粒子相对应的范围和与其他粒子相对应的范围分开。一组或一范围的形状因数的幅度是该组或该范围的上限和下限之差。术语“几乎未展示”表示“不包括超出与具有细长形状的粒子相对应的范围的主峰的30%、20%甚或10%的任一峰。因此,在一个实施方式中,具有细长形状的粒子由所述曲线上的孤立的主峰表示。
利用以上描述的方法测量的具有细长形状的粒子的数目大于0.05%、优选地大于0.10%、优选地大于0.15%、优选地大于0.20%、优选地大于0.25%、优选地大于0.3%、甚或大于0.4%和/或小于5%、甚或小于3%、优选地小于2%、优选地小于1%。
分析显示,具有细长形状的这些粒子包括元素Al和作为添加剂添加的氧化物的金属阳离子(Ca和/或Mn和/或Zn和/或La和/或Pr和/或Sr和/或Cu和/或Nd和/或Ba和/或Fe)。具有细长形状的所述粒子还可包括元素Ce。
发明人还示出,本发明的烧结颗粒中的氧化锆的体积的超过60%、优选地超过80%、更优选地超过90%是四方晶相。
CeO2和Y2O3起到稳定所述氧化锆的作用,但是其也可位于氧化锆外。
示例
为了说明本发明,给出以下非限制性示例。
烧结珠自以下制备:氧化锆源(比表面积大约为8m2/g;粒度中值<5μm)、CeO2源(粒度中值<10μm)、Y2O3源(粒度中值<20μm)、氧化铝源(粒度中值<5μm)以及根据所进行的示例的锰的氧化物的源,所述锰的氧化物的源原则上以Mn3O4形式(D90小于44μm)且还包括MnO。氧化锆源和CeO2源的纯度大于99%。锰的氧化物(以MnO表示)的源的纯度大于88%。混合这些粉末,并接着在湿性介质中共研磨,直到获得细粒度的混合物为止(粒度中值<0.3μm)。接着使所述混合物干燥。
按干燥物质的重量百分比计,水性悬液包括7.5%的聚丙烯酸类型的分散剂、1%的碳酸酯类型的反絮凝剂(粘度稳定剂)和1%的胶凝剂(即来自于褐藻胶族的多聚糖),接着从所述混合物制备所述水性悬液。
球研磨机用于该制备以获得悬浮液的良好均质性:首先形成包括所述胶凝剂的溶液。接着连续地,将可选的锰的源、氧化铝粉末、ZrO2粉末、CeO2粉末、Y2O3粉末和分散剂添加至水中。接着添加包括胶凝剂的溶液。将所获得的混合物搅拌8小时。接着添加反絮凝剂并将该混合物搅拌0.5小时。利用Micromeritics提供的Sedigrah 5100来通过沉降来监测粒度,并添加预定量的水以获得具有61%的干燥物质和小于8500cp[厘泊]的粘度的悬浮液,所述粘度是利用布鲁克菲尔德粘度计测量的。则该悬浮液的pH大致为9。
强制所述悬浮液以一流速流过校正孔使得在本发明的背景下的烧结之后,允许获得大致为1.2mm到1.4mm的珠。悬浮液的液滴进入基于电解质的胶凝浴中,所述电解质是与所述胶凝剂反应的二价或三价的阳离子盐。收集未经烧制的珠并洗涤所述珠以去除过量的试剂,接着在90℃下干燥所述珠以去除水分。接着将所述珠转移到烧结炉中,在该烧结炉中,以100℃/h的速度加热所述珠至所需的烧结温度。在所需的烧结温度下,4h的恒温阶段结束时,通过自然冷却使温度降低。
对具有各种组分并利用以上描述的方法获得的烧结珠进行两组测试。在第一组测试中,烧结温度在1375℃下保持恒定,并观察在不依赖于烧结温度的情况下所述珠的组分对其耐磨性的影响。在第二组测试中,改变烧结温度以观察其对所使用的各种组分的耐磨性的影响。
测量方案
为了确定“行星式”耐磨性,对20mL[毫升](利用刻度管测量体积)尺寸在1.25mm到1.4mm的范围(通过筛选选择)中的待测试的烧结颗粒进行称重(质量m0)并将其添加到来自RETSCH的型号PM400的快速行星式研磨机的4个涂覆有密实的烧结氧化铝且容积为125mL的磨盘中。将来自供应商Presi的2.2g[克]碳化硅(粒度中值D50为23μm)和40mL的水添加到所述磨盘的一个磨盘中。将所述磨盘封闭并以400rpm[转每分]旋转(行星运动),在1小时30分钟期间每隔一分钟使旋转方向反向。接着在100μm的筛子上洗涤所述磨盘的内容以移除残余的碳化硅以及在研磨期间由摩擦产生的碎片。在100μm的筛子上筛选之后,在100℃下烘干所述烧结颗粒3小时,接着称重(质量m)。
行星式损耗量(以百分比表示)由以下公式给出:
100(m0-m)/m0
利用“平均线性截距”方法测量所述烧结颗粒的平均粒度。标准ASTM E1382中描述了该类型的一种方法。在该标准中,在颗粒的图像上绘制分析线,接着沿着每一分析线测量切割所述分析线的两个连续晶界之间的称为“截距”的长度。
接着,确定截距“I”的平均长度“l′”。
对于以下测试,在颗粒的已抛光截面的通过扫描电子显微镜获得的图像上测量所述截距,所述部分已被抛光以获得镜面,接着在低于烧结温度100℃下进行热处理以显示出晶界。选择用来拍摄图像的放大倍数以在一个图像上察看大致100个粒子。每个颗粒产生5个图像。
烧结颗粒的粒子的粒度中值“d”由以下关系式给出:
d=1.56×l′
该公式由下列中的公式(13)得出:“Average Grain Size in polycrystallineCeramics”,M.I.Mendelson,J.Am.Cerm.Soc.第52卷,第8期,第443页-446页。
利用Journal of the American Chemical Society 60(1938)的第309页到316页中描述的BET(Brunauer Emmet Teller)方法测量比表面积。
发明人认为,在140℃下热压24小时之后,单斜晶氧化锆含量和耐磨性的小的改变对应于水热条件下的良好耐磨性。在这样的环境下,表2的最后一列示出测试产品在水热条件下稳定。
下面的表1和表2总结了获得的结果。
表2
(*):非根据本发明的示例
(**):Nd:测不到
发明人认为当在以下时,在研磨产率和行星式损耗量之间有非常好的折中:
-当行星式损耗量小于或等于3%时;以及
-密度在4.5g/cm3到5.9g/cm3的范围中时。
优选地,行星式损耗量小于2.5%、优选地小于2%、甚或小于1.5%、甚或小于1.0%,和/或密度在4.8g/cm3到5.5g/cm3的范围中、甚或在4.9g/cm3到5.3g/cm3的范围中。
对于示例3,,不包括除了CaO以外的添加剂化合物,高于1400℃的烧结温度是达到满足折中条件的耐磨性所必须的。因此,选择性地除了CaO以外,添加与CaO不同的添加剂化合物是有利的。
示例3和示例4的比较具体示出了在给定CaO含量下,锰的氧化物的存在的重要性。
CeO2的摩尔含量大于10%的示例5和示例6示出了为了实现满足折中条件的耐磨性而需要烧结温度高于1400℃。根据本发明的CeO2的优选范围意味着可以有利地限制烧结温度。这些示例还证实了CaO含量的有限提高的积极效果。
CaO含量为4.53%的示例10说明了限制CaO含量的重要性。
CeO2和Y2O3的含量未在用于本发明的制品的范围内的示例11在水热条件下不够耐磨。
示例2是最优选的示例。
表2还示出了所获得的性能和具有细长形状的粒子的比例之间的关系。
如本文清楚地示出,本发明提供了一种在行星式耐磨性和密度之间具有良好折中(即使是在水热条件下)的烧结颗粒。
显然,本发明不局限于以上描述的示例和实施方式。具体地,其它的胶凝系统可以适于制造本发明的陶瓷珠。因此,US5466400、FR2842438和US4063856描述了适用的溶胶凝胶法。FR2842438和US4063856利用与以上描述的胶凝系统(基于褐藻胶)接近的胶凝系统,而US5466400描述了一种非常不同的胶凝系统。
还可以设想US2009/0036291中描述的方法和通过按压或通过粒化作用形成珠的方法。
Claims (23)
1.一种烧结颗粒,所述烧结颗粒的最小直径和最大直径之间的比率大于0.6并且所述烧结颗粒具有按重量百分比计的以下化学分析:
·用CeO2和Y2O3部分稳定化的ZrO2:补充至100%的余量;
·Al2O3:10%-60%;
·选自CaO、锰的氧化物、La2O3、SrO、BaO和它们的混合物的添加剂:0.2%-6%;
·CaO,其量小于:2%;
·杂质:<2%;
·所述氧化锆被满足以下条件的摩尔量的CeO2和Y2O3稳定化,按基于ZrO2、CeO2和Y2O3的总和的摩尔百分比计:
·CeO2:6mol%-11mol%;以及
·Y2O3:0.5mol%-2mol%;
·所述颗粒是通过在高于1300℃的烧结温度下烧结而获得的,如果所述添加剂是CaO或如果CeO2的摩尔含量在10%到11%的范围中,所述烧结温度高于1400℃。
2.如权利要求1所述的烧结颗粒,其中所述CeO2的摩尔含量小于10%并且大于7%。
3.如权利要求2所述的烧结颗粒,其中所述CeO2的摩尔含量小于9.5%并且大于8.5%。
4.如前述任一项权利要求所述的烧结颗粒,其中所述Y2O3的摩尔含量小于1.2%并且大于0.8%。
5.如前述任一项权利要求所述的烧结颗粒,其中按基于氧化物的重量百分比计,所述氧化铝Al2O3的含量大于15%并且小于55%。
6.如前一项权利要求所述的烧结颗粒,其中按基于氧化物的重量百分比计,所述氧化铝Al2O3的含量大于20%并且小于40%。
7.如前述任一项权利要求所述的烧结颗粒,其中所述添加剂选自CaO、MnO、MnO2、Mn2O3、Mn3O4、La2O3、SrO和它们的混合物。
8.如前一项权利要求所述的烧结颗粒,其中所述添加剂选自CaO、MnO、Mn3O4和它们的混合物。
9.如前一项权利要求所述的烧结颗粒,其中所述添加剂是CaO与MnO和/或Mn3O4的混合物。
10.如前述任一项权利要求所述的烧结颗粒,其中按基于氧化物的重量百分比计,所述添加剂的含量大于0.4%并且小于5%。
11.如前一项权利要求所述的烧结颗粒,其中按基于氧化物的重量百分比计,所述添加剂的量大于0.5%并且小于1%。
12.如前述任一项权利要求所述的烧结颗粒,其中按基于氧化物的重量百分比计,所述添加剂的量小于4%。
13.如前述任一项权利要求所述的烧结颗粒,其中所述添加剂包括CaO,按基于氧化物的重量百分比计,CaO的量大于0.3%并且小于1.5%。
14.如前述任一项权利要求所述的烧结颗粒,其中所述杂质的量小于1%。
15.如前述任一项权利要求所述的烧结颗粒,其中所述烧结颗粒为圆球度大于0.7的珠的形式。
16.如前述任一项权利要求所述的烧结颗粒,其中所述烧结颗粒包括具有细长形状的粒子,由X-射线衍射测得的所述具有细长形状的粒子的量在0.05%到5%的范围中。
17.如前述任一项权利要求所述的烧结颗粒,其中按体积计所述氧化锆的超过80%为四方晶相。
18.如前述任一项权利要求所述的烧结颗粒,其中所述烧结颗粒是由包括滴铸步骤的方法制造的。
19.一种颗粒混合物,所述颗粒混合物包括:颗粒ZrO2、Al2O3、CeO2和Y2O3,以及选自CaO和/或锰的氧化物和/或La2O3和/或SrO和/或BaO和/或这些氧化物的前体颗粒的添加剂,它们成比例使得通过烧结所述颗粒混合物,可以获得前述任一项权利要求所述的烧结颗粒。
20.如前一项权利要求所述的颗粒混合物,其中粒度中值小于1μm。
21.如前一项权利要求所述的颗粒混合物,其中所述粒度中值小于0.3μm。
22.一种研磨机,所述研磨机包括权利要求1到18中任一项所述的烧结颗粒或由权利要求19-21中任一项所述的颗粒混合物制成的烧结颗粒。
23.权利要求1到18中任一项所述的烧结颗粒或由权利要求19到21中任一项所述的颗粒混合物制成的烧结颗粒用作研磨介质的用途。
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CN105777087A (zh) | 2016-07-20 |
JP5653423B2 (ja) | 2015-01-14 |
RU2011148477A (ru) | 2013-07-20 |
EP2438029B1 (fr) | 2013-10-23 |
ES2441842T3 (es) | 2014-02-06 |
FR2946337B1 (fr) | 2011-08-05 |
JP2012528782A (ja) | 2012-11-15 |
AU2010255358A1 (en) | 2011-12-15 |
AU2010255358B2 (en) | 2014-04-24 |
CA2763679A1 (fr) | 2010-12-09 |
CA2763679C (fr) | 2018-08-07 |
KR20120036933A (ko) | 2012-04-18 |
US20120082849A1 (en) | 2012-04-05 |
US8614001B2 (en) | 2013-12-24 |
SI2438029T1 (sl) | 2014-01-31 |
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