Summary of the invention
Namely technical problems to be solved in this application are to provide a kind of sintering Fe-Al base alloy porous material of resistance to high temperature oxidation and apply its filtering element.A kind of preparation method of sintering Fe-Al base alloy porous material of resistance to high temperature oxidation will be provided in addition.
The sintering Fe-Al base alloy porous material of the resistance to high temperature oxidation of the application, its porosity is 30 ~ 60%, and mean pore size is 0.5 ~ 50 μm, and has following feature:
A) it is elementary composition primarily of Fe, Al, Cr tri-kinds, and the weight sum of these three kinds of elements accounts for more than 90% of this sintering FeAl base alloy porous material weight, and wherein, Fe is 60 ~ 85%, Cr of Fe, Al gross weight is 10 ~ 30% of Fe, Al, Cr gross weight;
B) Cr in this sintering Fe-Al base alloy porous material mainly exists with the form of the chromium compounds of Fe-Al based compound, or mainly exist with the form of the chromium compounds of Fe-Al based compound and FeCr, and be uniformly distributed haply in this sintering Fe-Al base alloy porous material;
C) its tensile strength>=45MPa, the sintering Fe-Al base alloy porous material air flux>=80m of thickness≤5mm
3/ m
2kpah, be that in the NaOH solution of 10%, the rate of weight loss of soaking at room temperature after 15 days is below 0.5% at massfraction, and under the air atmosphere of 1000 DEG C, be incubated material rate of body weight gain after 90 hours be less than 0.25%.
Above-mentioned sintering Fe-Al base alloy porous material can be only elementary composition by Fe, Al, Cr tri-kinds, also other materials except Fe, Al, Cr can be added in the scope being no more than sintering Fe-Al base alloy porous material gross weight 10%, such as, in Mo, V, Nb, Si, W, Y, Ta, Zr, Co one or more elements.The weight sum of Fe, Al, Cr tri-kinds of elements in this porous material controls in more than 95%, 97%, 98% or 99% of porous material weight by current suggestion, thus the performance sintering Fe-Al base alloy porous material can either be ensured, also can simplify raw material type simultaneously, be convenient to produce.
When sintering Fe-Al base alloy porous material and being elementary composition by Fe, Al, Cr tri-kinds, according to the change of Cr content, the composition of the crystallization phases in this sintering Fe-Al base alloy porous material can comprise following several situation:
1) crystallization phases of this sintering Fe-Al base alloy porous material is made up of compound between Fe-Al binary metal and Fe-Al-Cr ternary compound, and described Fe-Al-Cr ternary compound is specially Fe
2alCr;
2) crystallization phases of this sintering Fe-Al base alloy porous material is made up of Fe-Al-Cr ternary compound, and described Fe-Al-Cr ternary compound is specially Fe
2alCr.
3) crystallization phases of this sintering Fe-Al base alloy porous material is made up of Fe-Cr binary compound and Fe-Al-Cr ternary compound, and described Fe-Al-Cr ternary compound is specially Fe
2alCr, Fe-Cr binary compound is specially FeCr.
The filtering element of the application, this filtering element contains the sintering Fe-Al base alloy porous material of above-mentioned resistance to high temperature oxidation.In view of material behavior, described filtering element is preferably a kind of filtering element for gas filtration, is especially a kind of filtering element of the high temperature air filtration for 300 ~ 800 DEG C.
The preparation method of the sintering Fe-Al base alloy porous material of the above-mentioned resistance to high temperature oxidation of the application, its step comprises:
1) mixed powder is prepared: be 200 ~ 300 object Fe powder by particle diameter, particle diameter to be 200 ~ 300 object Al powder and particle diameter be-400 object Cr powder mix by the proportioning of to be 60 ~ 85%, Cr of Fe, Al gross weight be 10 ~ 30% of Fe, Al, Cr gross weight of Fe in the sintering Fe-Al base alloy porous material prepared;
2) granulation, drying and shaping: the mixed powder containing above-mentioned Fe powder, Al powder, Cr powder is carried out granulation, drying successively, drying temperature is set as 40 ~ 60 DEG C, be set as 4 ~ 8 hours time of drying, then pressure forming is carried out, under 120 ~ 280MPa forming pressure, pressurize 20 ~ 80 seconds, obtains pressed compact after pressure forming;
3) sinter: pressed compact is placed in sintering oven and sinters, sintering schedule comprises following four-stage: the first stage: sintering temperature rises to 420 ~ 500 DEG C from room temperature, temperature rise rate controls at 1 ~ 10 DEG C/min, and is incubated 60 ~ 300 minutes at 420 ~ 500 DEG C; Subordinate phase: sintering temperature is risen to 550 ~ 650 DEG C, temperature rise rate controls at 1 ~ 10 DEG C/min, and is incubated 180 ~ 360 minutes at 550 ~ 650 DEG C; Phase III: sintering temperature is risen to 1000 ~ 1100 DEG C, temperature rise rate controls at 1 ~ 15 DEG C/min, and is incubated 120 ~ 240 minutes at 1000 ~ 1100 DEG C; Fourth stage: sintering temperature is risen to 1200 DEG C ~ 1350 DEG C, temperature rise rate controls at 1 ~ 5 DEG C/min, and 120 ~ 360 minutes are incubated at 1200 DEG C ~ 1350 DEG C; After sintering, namely furnace cooling obtains the sintering Fe-Al base alloy porous material of resistance to high temperature oxidation.
The sintering Fe-Al base alloy porous material of the application's resistance to high temperature oxidation has technique effect useful as follows:
One, there is higher tensile strength, excellent high-temperature oxidation resistance and anti-alkali corrosion performance;
Two, surprisingly, due in raw material Cr and Fe reaction and improve pore structure, reduce filtration medium through resistance, desirable filtration flux (ventilation property) can be obtained.
Embodiment
Below by experiment, the preparation method of sintering Fe-Al base alloy porous material and the sintering Fe-Al base alloy porous material that obtained by these methods are specifically described.Illustrated by these, those skilled in the art can know the outstanding feature recognizing that the sintering Fe-Al base alloy porous material of the application has.The numbering of the experimental example below related to is consistent with the numbering of corresponding " pressed compact ", " sample ".
For sintering Fe-Al base alloy porous material and the preparation thereof of the application are described, following 7 groups of experimental examples are prepared altogether.Wherein, the sample 1 to 4 that example 1 to 4 prepares respectively by experiment all belongs within the scope of the application's claim 1 claimed sintering Fe-Al base alloy porous material.Experimental example 5 to 7, as the contrast experiment embodying experimental example 1 to 4 substantive distinguishing features and technique effect, its numbering all uses " * " to mark, to distinguish.Experimental example 5 specifically decreases the content of Cr powder in raw material on the basis of experimental example 1, and is compared with sample 1 by the sample 5 prepared thus.Experimental example 6 specifically adds the content of Cr powder in raw material on the basis of experimental example 4, and is compared with sample 3 by the sample 6 prepared thus.Experimental example 7 relates to the preparation method of existing Fe-Al intermetallic compound porous material, and is compared with sample 1 to 4 by the sample 7 prepared thus.
One, material preparation process
The material composition of experimental example 1 to 7 and content (by weight percentage) are in table 1.Wherein have employed particle diameter is 200 ~ 300 object Fe powder, and particle diameter is 200 ~ 300 object Al powder, particle diameter to be-400 object Cr powder and particle diameter the be Si powder of 3 ~ 5 μm.
As can be seen from the material composition listed by table 1 and content thereof: the raw material of experimental example 1 is made up of Fe powder, Al powder and Cr powder, wherein Fe powder accounts for Fe powder, 75%, Cr powder of Al powder gross weight accounts for 10% of raw material gross weight; The raw material of experimental example 2 is made up of Fe powder, Al powder and Cr powder, and wherein Fe powder accounts for Fe powder, 77.5%, Cr powder of Al powder gross weight accounts for 26.5% of raw material gross weight; The raw material of experimental example 3 is made up of Fe powder, Al powder and Cr powder, and wherein Fe powder accounts for Fe powder, 75%, Cr powder of Al powder gross weight accounts for 30% of raw material gross weight; The raw material of experimental example 4 is made up of Fe powder, Al powder, Cr powder and Si powder, and 9.4%, the Si powder that wherein Fe powder accounts for Fe powder, 75%, Cr powder of Al powder gross weight accounts for raw material gross weight accounts for 6% of raw material gross weight; The raw material of experimental example 5 is made up of Fe powder, Al powder and Cr powder, and wherein Fe powder accounts for Fe powder, 75%, Cr powder of Al powder gross weight accounts for 5% of raw material gross weight; The raw material of experimental example 6 is made up of Fe powder, Al powder and Cr powder, and wherein Fe powder accounts for Fe powder, 75%, Cr powder of Al powder gross weight accounts for 35% of raw material gross weight; The raw material of experimental example 7 is made up of Fe powder, Al powder, wherein Fe powder account for Fe powder, Al powder gross weight 75%.
Table 1: the composition that experimental example 1 to 7 is raw materials used and content
By listed by table 1, respectively the raw material of experimental example 1 to 7 is mixed.After abundant mixing, consider in the raw material of experimental example 1 to 6 and be all mixed with the less Cr powder of particle diameter, easily cause segregation, therefore, also need to carry out granulation (for ease of contrast, carrying out granulation equally to the powder of experimental example 7) to the powder of experimental example 1 to 6, after granulation, carry out drying again, drying temperature is set as 55 DEG C, is set as 6 hours time of drying.Afterwards, loaded by the powder of experimental example 1 to 7 respectively in the isostatic pressing mold of unified specification, then these moulds are placed in cold isostatic compaction machine respectively, pressurize 60 seconds under 200MPa forming pressure, namely makes the tubulose pressed compact being numbered 1 to 7 after the demoulding.Then, these pressed compacts are respectively charged into sintering boat, then these sintering boats are placed in sintering oven sinter, furnace cooling after sintering, finally obtains sample 1 to 7 again from each sintering boat.
The sintering schedule of 1.1 experimental examples 1 to 6
The sintering schedule of experimental example 1 to 6 comprises following four-stage.First stage: sintering temperature rises to 420 ~ 500 DEG C from room temperature, temperature rise rate controls at 1 ~ 10 DEG C/min, and is incubated 60 ~ 300 minutes at 420 ~ 500 DEG C; Subordinate phase: sintering temperature is risen to 550 ~ 650 DEG C, temperature rise rate controls at 1 ~ 10 DEG C/min, and is incubated 180 ~ 360 minutes at 550 ~ 650 DEG C; Phase III: sintering temperature is risen to 1000 ~ 1100 DEG C, temperature rise rate controls at 1 ~ 15 DEG C/min, and is incubated 120 ~ 240 minutes at 1000 ~ 1100 DEG C; Fourth stage: sintering temperature is risen to 1200 DEG C ~ 1350 DEG C, temperature rise rate controls at 1 ~ 5 DEG C/min, and 120 ~ 360 minutes are incubated at 1200 DEG C ~ 1350 DEG C; After sintering, namely furnace cooling obtains the sintering Fe-Al base alloy porous material of resistance to high temperature oxidation.
The main purpose of above-mentioned first stage is degreasing; Subordinate phase is middle temperature step of reaction, main purpose is that facilitating Fe and Al to react pore-creating generates compound between Fe-Al binary metal, facilitate Fe and Cr to react pore-creating and generate FeCr, react with compound between Fe-Al binary metal and FeCr simultaneously and generate Fe-Al-Cr ternary compound Fe
2alCr; Phase III is the pyroreaction stage, and main purpose is to facilitate further reacts and generates Fe
2alCr; Fourth stage is holding stage, and it is abundant that main purpose is to make sintering, and promote the lifting of even structure and performance.For suppressing the volatilization of hot stage lightweight element, above-mentioned phase III and fourth stage can adopt protection of inert gas to sinter; Or, also suitably can adjust proportioning raw materials to compensate the volatile quantity of lightweight element.
In the sintering process of experimental example 1 to 6, the sintering process parameter of four-stage is specifically as shown in table 2.In table 2, the unit of temperature rise rate is DEG C/min, and the unit of sintering time is minute.
Table 2: the sintering schedule of experimental example 1 to 6
The sintering schedule of 1.2 experimental examples 7
Sintering schedule comprises three phases.Sintering temperature rises to 500 DEG C from room temperature, and temperature rise rate controls at 5 DEG C/min, and is incubated 60 minutes at 500 DEG C; Subordinate phase: sintering temperature is risen to 630 DEG C, temperature rise rate controls at 3 DEG C/min, and 630 times insulations 300 minutes; Phase III: sintering temperature is risen to 1100 DEG C, temperature rise rate controls at 5 DEG C/min, and is incubated 120 minutes at 1100 DEG C.After sintering, namely furnace cooling obtains sintering Fe-Al base alloy porous material.
Two, the phase composite of material and performance measurement thereof
Detected sample 1 to 7 respectively by XRD, its result is: the phase composite of sample 1 is compound (FeAl) and Fe between Fe-Al binary metal
2alCr(is as Fig. 2); The phase composite of sample 2 is Fe
2alCr; The phase composite of sample 3 is Fe
2alCr and FeCr; The phase composite of sample 4 is compound, Fe between Fe-Al binary metal
2alCr and Fe
3si; The phase composite of sample 5 is compound and Fe between Fe-Al binary metal
2alCr; The phase composite of sample 6 is Fe
2alCr and FeCr; The phase composite of sample 7 is compound between Fe-Al binary metal.
Visible, the phase composite of the sintering Fe-Al base alloy porous material of the application is relevant with Cr content.When not mixing other elements, when Cr content is relatively less, the crystallization phases of sintering Fe-Al base alloy porous material is by compound and Fe between Fe-Al binary metal
2alCr forms (as samples 1); When Cr content increases to a certain degree, the crystallization phases of sintering Fe-Al base alloy porous material is by Fe
2alCr forms (as samples 2); When Cr content increases further, the crystallization phases of sintering Fe-Al base alloy porous material is by Fe
2alCr and FeCr forms (as samples 3).Between Fe-Al binary metal, compound can be Fe according to material rate
3al, FeAl.
The performance test of sample 1 to 7 is as table 3.Wherein, the mensuration of material porosity and mean pore size adopts bubble method; Filtration flux is specially on every m filter area, every kpa filtration pressure difference and per hour under air flux; The test of Tensile strength is recorded by drawing machine after sample 1 to 7 is processed as standard test specimen by CNS GB7963-87; It is that in the NaOH solution of 10%, the rate of weight loss of soaking at room temperature after 15 days characterizes that material erosion resistance adopts at massfraction; The high temperature oxidation resistance of material is that be incubated 90 hours under the air atmosphere of 1000 DEG C after, material rate of body weight gain characterizes.
Table 3: the performance test results of sample 1 to 7
Three, test result analysis
1) total result is tested see table 3.Wherein, the tensile strength degree of sample 1 to 4 all>=45MPa, thickness is about the sintering Fe-Al base alloy porous material air flux>=80m of 5mm
3/ m
2kpah(is obvious, thickness is less on this basis, flux will increase further), be that in the NaOH solution of 10%, the rate of weight loss of soaking at room temperature after 15 days is below 0.5% at massfraction, and under the air atmosphere of 1000 DEG C, be incubated material rate of body weight gain after 90 hours be less than 0.25%.And equal incapability reaches tensile strength degree>=45MPa in sample 5 and 7 simultaneously, air flux>=80m
3/ m
2kpah, be that in the NaOH solution of 10%, the rate of weight loss of soaking at room temperature after 15 days is below 0.5% at massfraction, and under the air atmosphere of 1000 DEG C, be incubated material rate of body weight gain after 90 hours be less than 0.25% person.
2) about the tensile strength of material, erosion resistance and high temperature oxidation resistance.The tensile strength of sample 1,4 is respectively 48MPa and 55MPa, close to lower value 45MPa; The tensile strength of sample 2,3 and 6 enlarges markedly, and reaches more than 60MPa.The erosion resistance of sample 1,4 and high temperature oxidation resistance are all lower than sample 2,3 and 6.This shows, after Fe, Al content is determined, tensile strength, the erosion resistance of material are all relevant to Cr content with high temperature oxidation resistance, and namely Cr content increases, and tensile strength, erosion resistance and high temperature oxidation resistance are all corresponding to be increased.Sample 7 is not containing Cr, therefore tensile strength, erosion resistance and high temperature oxidation resistance are minimum.In sample 5, Cr content is less, though therefore tensile strength higher than sample 7, but still lower than 45MPa, and erosion resistance and high temperature oxidation resistance are not very good yet.
3) about the perviousness of material.In sample 1 to 7, except the air flux of sample 2,3 and 4 is obviously high, the air flux of all the other samples is close; In addition, change from the air flux of sample 1 to 6, when porosity and mean pore size basically identical, when Cr is less than 30% of Fe, Al, Cr gross weight, with increasing of Cr content, air flux increases gradually, and after Cr content is more than 30% (as samples 6), air flux starts to decline.This shows, when the incorporation of Cr is less than 30% of Fe, Al, Cr gross weight, Cr and the Fe in raw material reacts and improves pore structure, can make up the impact that Al content declines on pore-creating and porosity, reduce filtration medium through resistance, desirable filtration flux can be obtained.
4) in general, in order to reach more excellent comprehensive use properties, the Fe that the application sinters in Fe-Al base alloy porous material can account for Fe, Al gross weight 70%, 73%, 76%, 80%, and the Cr in sintering Fe-Al base alloy porous material can account for Fe, Al, Cr gross weight 20%, 24%, 26% or 28%.In view of the more common Fe-Al intermetallic compound porous material of these sintering Fe-Al base alloy porous material at high temperature oxidation-resistances is significantly improved, therefore, the sintering Fe-Al base alloy porous material of the application is very suitable for making the filtering element for gas filtration, in particular for the filtering element of the high temperature air filtration of 300 ~ 800 DEG C.