CN104072111A - Preparation method of aluminium oxide honeycomb ceramics - Google Patents
Preparation method of aluminium oxide honeycomb ceramics Download PDFInfo
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Abstract
The invention discloses a preparation method of aluminium oxide honeycomb ceramics. The preparation method comprises the following steps: 1) preparing aluminium oxide honeycomb blank bodies with parallel pore passages; 2) dumping or degreasing the aluminium oxide honeycomb blank bodies; and 3) calcining the aluminium oxide honeycomb blank bodies to obtain the aluminium oxide honeycomb ceramics with pore passage inner wall extending whisker structures. The ceramic matrix part particles prepared by the method are tightly bonded and whiskers grow on the honeycomb pore inner walls. The honeycomb ceramics have the excellent properties such as high temperature resistance and chemical corrosion resistance and are suitable for filtration and purification of various fluids. According to the used honeycomb ceramics, filtered matters are easily removed by adopting various methods and the honeycomb ceramics can be reused. The preparation method is simple in process, is low in equipment requirements, is convenient in operation control, has high production efficiency and is suitable for large-scale industrial production.
Description
Technical field
The present invention relates to material technology field, particularly, relate to one and have the preparation method of the cellular alumina pottery of " duct inner wall extend whisker " structure.
Background technology
Ceramic honey comb has the pore texture of parallel perforation, have that osmotic pressure is high, geometric jacquard patterning unit surface is large, diffusion length is short, be conducive to counting of particle and discharge with gas and dwindle advantages such as filtering volume, have a wide range of applications at aspects such as filtration, purification, the heat exchange of metallurgical industry and the filtration of molten metal, the toxic gas of mining industry and the purifying treatment of liquid of industrial gaseous waste, motor-vehicle tail-gas and other life waste gas.
What the technology of preparing of ceramic honey comb was the most ripe at present is extrusion moulding, first prepare mould according to the size of required honeycomb hole and shape (trilateral, rhombus, rectangle, hexagon etc.), then prepare the ceramic honey comb of duct arrangement high-sequential by the extrusion of ceramic size.Corning company of the U.S. and Japanese NGK company have realized industrialization and have produced, and the ceramic honey comb of preparation is mainly used in vehicle exhaust and heat accumulation block materials.
The greatest problem of the method is that material aperture is limited by the preparation of mould, is difficult to prepare the cellular material of aperture in tens micron dimensions, thereby has limited the further performance of the performance such as honeycomb ceramic filter, heat accumulation.The up-to-date ceramic honey comb product of Corning company can be prepared at most 1200 through holes on the cross section of 1 square inch, is that current known the method can be prepared the limit in ceramic honey comb aperture, and further reduced bore is very difficult.This is focus and difficult point in the preparation research of ceramic honey comb.
The aperture that enables further to reduce ceramic honey comb is reduced to micron dimension, its aperture dwindle the increase suddenly that will cause gas to pass through resistance, thereby reduce its working efficiency., relying on single honeycomb structure to be difficult to solve subparticle filters desired small-bore and keeps unimpeded this contradiction of air-flow simultaneously.
Whisker is the single crystal of a kind of high strength beard shape synthetic under manual control condition, and its crystalline structure is more complete, and subsurface defect is few, and its strength and modulus all approaches ideal crystal.Therefore, whisker Chang Zuowei reinforcing component join metal matrix, ceramic base and polymer-based in it strengthens toughness reinforcing effect.Modal whisker has Si
3n
4, SiC, Al
2o
3deng.But at present mainly concentrate on the preparation of whisker about the research of whisker and matrix is strengthened on toughening effect, the research about whisker in other purposes rarely has report.In the preparation research of whisker, there is report to point out to utilize the hole can growth in situ whisker, as patent CN102251284A (a kind of method of preparing beta-alumina whisker), and document (Ji Xiaoli, Xu Fei, power its people, Wan Weiwei, On In-situ Synthesis of Mullite Whisker And strengthens foam silicon carbide ceramics, Chinese powder technology, 2011,17 (3): 33-36) and document (Lv Chenjing, Tian Xiushu, Han Yufang, the synthetic Al that contains of original position
2o
3whisker Al
2o
3the research of/Ti-Al matrix material mechanism), but former concerns is in the preparation of whisker, both pay close attention to the reinforced effects of whisker to matrix or foam base plate afterwards.Meanwhile, the hole in porous body and parts that above document is prepared is closed pore, is difficult to use in filtration.
How having overcome the dependence of legacy cellular pottery working efficiency to aperture and unit surface hole count, and then increased the filtration of pottery to fine particle, and ensured the unimpeded of fluid, is the new demand to ceramic structure of current honeycomb ceramic filter and field of purification.
Summary of the invention
The preparation method who the invention provides a kind of cellular alumina pottery, comprises the following steps:
1) preparation has the cellular alumina base substrate in parallel duct and is dried;
2) dried base substrate is carried out to organic eliminating;
3) Calcined polishing aluminum oxide honeycomb base substrate, obtains body portion particle in conjunction with tight, and hole inner wall extend has the cellular alumina pottery of whisker.
Wherein, in step 1), there is the cellular alumina base substrate employing extrusion moulding preparation in parallel duct.In the art, extruding forming method is to prepare the method that ceramic honey comb is conventional, can directly prepare cellular alumina base substrate.
In the inventive method, in step 1), cellular alumina base substrate also can adopt dry pressing, gel casting forming method or direct coagulation casting method first to prepare biscuit, then adopts mechanical hole building method to make to have the cellular alumina base substrate in parallel duct.
In multiple embodiment of the present invention, be to adopt Multi needle to become punch die, make the cellular alumina base substrate with parallel duct.
In the inventive method, in step 1), taking alumina powder jointed as raw material, and add sintering agent, shaping medium, dispersion agent to mix, prepare cellular alumina base substrate base substrate.
Described alumina powder jointed particle diameter 0.5 μ m～3 μ m, accounts for total powder 65～75wt%.
Described sintering agent is kaolin, CaCO
3, BaCO
3, MgCO
3, talcum, rhombspar and/or wollastonite, wherein, kaolin content is total powder quality 9～20%, CaCO
3content is 0～3% of total powder quality, BaCO
3content is 0～3% of total powder quality, MgCO
3content is 0～3% of total powder quality, and talc content is total powder quality 0～2%, and rhombspar content is total powder quality 0～9%, and wollastonite content is total powder quality 0～2%.
Described total powder is the summation of aluminum oxide, sintering agent, shaping medium, dispersion agent powder.
Dispersion agent is mainly used in the colloidal formation such as gel injection molding and forming technology, direct coagulation casting technique, and the present invention does not also rely on specific dispersion agent, as long as dispersion agent can make ceramic powder suitably disperse in sauce.The example of some operable dispersion agents is ammonium polyacrylate, ammonium citrate, ammonium polymethacrylate etc.
According to different forming methods, select corresponding shaping medium.Extrusion moulding generally selects water, polyvinyl alcohol, poly-hydroxyl ethanol acid etc. as shaping medium.It is shaping medium that gel casting forming is selected water base acrylamide polymerization system, and wherein monomer is acrylamide, and linking agent is N, N '-methylene-bisacrylamide, and initiator is 8% ammonium persulfate solution, catalyzer is N,N,N′,N′ tetramethylethylene diamine.It is shaping medium that direct coagulation casting is selected urea and urease.
The additive such as raw alumina powder, sintering agent powder and dispersion agent, shaping medium involved in the present invention is common commercial powder, its purity is commercial level, but can, further according to the requirement of product purity is adjusted, also can adopt the rank reagent such as analytical pure.
The more little sintering that is more conducive to of powder granularity of raw alumina powder, sintering agent powder and dispersion agent, shaping medium etc. involved in the present invention, the preferably following powder of 2.0 μ m, but be not limited to this scope.
According to different forming methods, additive can be different as dispersion agent, moulding reagent etc., and the solid load of base substrate also can be different.
In the inventive method, step 2) in cellular alumina base substrate dry, room temperature is dried in the shade or 40 DEG C～60 DEG C oven dry, keeps the parallel construction in honeycomb duct.
According to different forming methods, its time of drying/temperature/humidity is different, to keep base substrate indeformable as standard.Because of organic content difference in different forming method base substrates, so it is different to get rid of organic program.In extrusion moulding, dry-pressing formed prepared base substrate, organic content is higher, depending on base substrate size, need the independent degreasing program of 1 hour to 1 day, and in the prepared base substrate of gel casting forming and direct coagulation casting, organic content is lower, is easy to binder removal in the rapid heating condition before sintering.This process is familiar with by those skilled in the art.
Step 2) in dried base substrate is carried out to organism eliminating, temperature is at 500 DEG C～800 DEG C, the time is 0.5～3h.
In the inventive method, in step 3), cellular alumina base substrate is calcined, calcining temperature is 1580 DEG C～1600 DEG C, insulation 1h～3h.
Preferably, in step 3), cellular alumina base substrate is calcined, calcining temperature is 1600 DEG C, insulation 3h.
The present invention proposes on the framework of ceramic honey comb base substrate, utilize the principle of hole growth whisker, the whisker of preparing hole wall and be stretching, extension in this novel texture cellular alumina pottery duct of cellular alumina pottery of " whisker intert parallel duct " novel texture of whisker can effectively carry out the filtration of fine particle, and its original basic honeycomb parallel via holes structure has ensured the smoothness of fluid.
The present invention is based on hole the principle that space can growth in situ whisker is provided, select Al
2o
3for raw material, by controlling sintering condition, prepare the novel aluminum oxide ceramic honey comb of " duct inner wall extend whisker ".The present invention, according to the pattern feature of whisker, utilizes the whisker of duct inner wall extend to increase the filtration to fine particle, utilizes parallel duct to ensure the unimpeded of fluid simultaneously, has overcome the dependence of legacy cellular pottery working efficiency to aperture and unit surface hole count.The present invention synthesizes whisker at honeycomb structure situ first, and has developed whisker new application in filtration and field of purification in conjunction with honeycomb structure.
Production technique of the present invention is simple, low for equipment requirements, convenient operation and control, and production efficiency is high, is applicable to large-scale industrial and produces.The ceramic honey comb of preparing by method of the present invention is alumina material, there is the premium propertiess such as high temperature resistant, resistance to chemical attack, be applicable to filtration and the purification of multiple fluid, the waste gas producing as fine particle in air, various commercial run, the filtration, purification of its other life waste gas of motor-vehicle tail-gas, also can be used for analyzing the tabular adsorbent of use chromatographic column, heat exchange to metallurgical industry and the filtration of molten metal, toxic gas and the purifying treatment of liquid etc. to mining industry.Scanning electron microscope (SEM) shows that ceramic honey comb body portion particle of the present invention is in conjunction with tight, and honeycomb hole inwall grows into whisker, forms parallel duct.This structure makes ceramic honey comb of the present invention can keep by straight-through duct in use the smoothness of fluid, and the whisker of passing hole channel inner wall extend further filters, cleansing fluid.
Brief description of the drawings
Fig. 1 is the SEM photo of alumina-ceramic " duct inner wall extend whisker ".
Fig. 2 is the XRD figure spectrum of alumina-ceramic " duct inner wall extend whisker ".
Embodiment
Following examples are used for illustrating the present invention, but are not used for limiting the scope of the invention.Without departing from the spirit and substance of the case in the present invention, the amendment that the inventive method, step or condition are done or replacement, all belong to scope of the present invention.
If do not specialize, in embodiment, chemical feedstocks used is conventional marketable material, the conventional means that in embodiment, technique means used is well known to those skilled in the art.
Cellular alumina pottery and performance thereof are prepared in embodiment 1 extrusion moulding
Get the aluminum oxide powder that 216g particle diameter is 3 μ m, 60g kaolin, 9g CaCO
3, 9gBaCO
3with 6g wollastonite, mix, obtain powdered mixture.Water, polyvinyl alcohol and the acid of poly-hydroxyl ethanol being pressed to the weight ratio of 70:10:20 mixes, stirring makes homogeneous solution, solution is mixed according to the weight ratio of 100:70 with above-mentioned powder mixture, normal temperature fully mixing 0.75 hour in mixing roll (BL-6175-B) at normal temperatures and pressures, under normal temperature and pressure old 3 hours, obtain pug.Pug is crossed to 60 mesh sieves and carry out filtration, purification, extrude honeycomb biscuit by honeycomb ceramic extruding machine (BL-6177), 40 DEG C are dried 6 hours, after dry, sample is removed organism 2h at 600 DEG C of binder removals, then the honeycomb biscuit after binder removal is put into retort furnace (BTF-1700C), be warming up to 1580 DEG C of insulations 3 hours with 10 DEG C/min, there is the cellular alumina pottery of " duct inner wall extend whisker " structure.Fig. 1 is shown in by its SEM photo, and XRD figure is shown in Fig. 2.The cellular alumina ceramic matrix part particle that SEM Image Display the present embodiment makes is in conjunction with tight, and honeycomb hole inwall grows into whisker, forms parallel duct.
This ceramic honey comb aperture is 0.5mm, and void content is 68%.The method specifying according to GB/T1964 detects, and obtaining horizontal ultimate compression strength is 9MPa, axial compression strength 21MPa.Ceramic honey comb is boiled after 0.5 hour and placed after 24 hours again with 10% salpeter solution, and solution is water white transparency, and resist chemical performance is good.After testing, the cellular alumina pottery that prepared by the present invention has that osmotic pressure is high, geometric jacquard patterning unit surface is large, diffusion length is short, be conducive to counting of particle discharges with gas and dwindles filtration volume, the excellent specific properties such as the smoothness of fluid.
Embodiment 2 gel casting formings are prepared cellular alumina pottery and performance thereof
By monomer acrylamide and linking agent N, N '-methylene-bisacrylamide is water-soluble, and monomer concentration is 15wt%, crosslinker concentration is 0.5wt%, forms monomer premixed liquid, and in 100ml monomer premixed liquid, adding 140g particle diameter is the aluminum oxide powder of 1 μ m, 40g kaolin, 6gMgCO
3, 6g BaCO
3with 4g talcum, dispersion agent is ammonium citrate 2g, stirs and obtains uniform ceramic size, in above-mentioned slurry, add catalyst n, N, N ', N '-Tetramethyl Ethylene Diamine 25 μ l, then stir, then add initiator 8% ammonium persulfate solution 50 μ l, after stirring, inject at once mould, and will make Multi needle by oneself and become punch die (syringe needle φ=2mm, 4 hole/square centimeters) to insert in slurry, the demoulding after slurry is gel, obtains the wet base of honeycomb.The base that will wet is put into 50 DEG C, baking oven and is dried 24 hours, dry base substrate is put into retort furnace (BTF-1700C), be warming up to 1600 DEG C with 10 DEG C/min of speed, organism completes eliminating in temperature-rise period, 1600 DEG C of sintering 2 hours, are had the cellular alumina pottery of " duct inner wall extend whisker " structure.The cellular alumina ceramic-like that the SEM photo of the cellular alumina pottery that the present embodiment prepares and XRD figure and embodiment 1 make seemingly.
This ceramic honey comb aperture is 0.1mm, and void content is 68%.The method specifying according to GB/T1964 detects, and obtaining horizontal ultimate compression strength is 9MPa, axial compression strength 21MPa.Ceramic honey comb is boiled after 0.5 hour and placed after 24 hours again with 10% salpeter solution, and solution is water white transparency, and resist chemical performance is good.After testing, the cellular alumina pottery of preparation has that osmotic pressure is high, geometric jacquard patterning unit surface is large, diffusion length is short, is conducive to counting of particle and discharges with gas and dwindle filtration volume, the excellent specific properties such as the smoothness of fluid.
Dry-pressing formed cellular alumina pottery and the performance thereof prepared of embodiment 3
Be 3 μ m aluminum oxide powders by 210g particle diameter, 60g kaolin, 6g BaCO
3mix with 18g rhombspar powder, add alcohol and abrading-ball wet-milling 24 hours, after drying and screening, after adding to sieve, material is counted 5wt% paraffin as forming agent, in punching block, be pressed into rectangular sample (long 10cm, wide 5cm, high 5cm), pressure is 100MPa, be pressed into subsequently self-control Multi needle and become punch die (syringe needle φ=2mm, 4 hole/square centimeters) and extract, make honeycomb base substrate, this honeycomb base substrate is put into draft glue discharging furnace and be warming up to 800 DEG C and be incubated dewaxing in 3 hours, dry base substrate is put into retort furnace (BTF-1700C), be warming up to 1600 DEG C of sintering 2.5 hours with 10 DEG C/min of speed.There is the cellular alumina pottery of " duct inner wall extend whisker " structure.The cellular alumina ceramic-like that the SEM photo of the cellular alumina pottery that the present embodiment prepares and XRD figure and embodiment 1 make seemingly.
This ceramic honey comb aperture is 0.1mm, and void content is 62%.The method specifying according to GB/T1964 detects, and obtaining horizontal ultimate compression strength is 10MPa, axial compression strength 21MPa.Ceramic honey comb is boiled after 0.5 hour and placed after 24 hours again with 10% salpeter solution, and solution is water white transparency, and resist chemical performance is good.After testing, the cellular alumina pottery of preparation has that osmotic pressure is high, geometric jacquard patterning unit surface is large, diffusion length is short, is conducive to counting of particle and discharges with gas and dwindle filtration volume, the excellent specific properties such as the smoothness of fluid.
Embodiment 4 direct coagulation castings are prepared cellular alumina pottery and performance thereof
Alumina powder jointed and the 8.5g sintering agent aluminum oxide powder and the 255g yttrium oxide powder that are 1 μ m by 340g particle diameter mix, add 100ml deionized water fully to stir, slurry is cooled to 5 DEG C of left and right, add analytically pure urea 1g and urease 20unit/mg, be stirred well to evenly, slurry is warming up to 25 DEG C, become punch die to put into slurry Multi needle, static 1 hour, slurry curing, take out self-control Multi needle and become punch die (syringe needle φ=2mm, 4 hole/square centimeters), make cellular alumina base substrate.Base substrate is put into 40 DEG C, baking oven and be dried 12 hours, dry base substrate is put into dry base substrate is put into retort furnace (BTF-1700C), be warming up to 1600 DEG C with 10 DEG C/min of speed, organism completes eliminating in temperature-rise period, 1600 DEG C of sintering 3 hours, are had the cellular alumina pottery of " duct inner wall extend whisker " structure.The cellular alumina ceramic-like that the SEM photo of the cellular alumina pottery that the present embodiment prepares and XRD figure and embodiment 1 make seemingly.
This ceramic honey comb aperture is 0.1mm, and void content is 72%.The method specifying according to GB/T1964 detects, and obtaining horizontal ultimate compression strength is 12MPa, axial compression strength 28MPa.Ceramic honey comb is boiled after 0.5 hour and placed after 24 hours again with 10% salpeter solution, and solution is water white transparency, and resist chemical performance is good.After testing, the cellular alumina pottery of preparation has that osmotic pressure is high, geometric jacquard patterning unit surface is large, diffusion length is short, is conducive to counting of particle and discharges with gas and dwindle filtration volume, the excellent specific properties such as the smoothness of fluid.
Embodiment 5 gel casting forming cellular alumina pottery and performances thereof
By monomer acrylamide and linking agent N, N '-methylene-bisacrylamide is water-soluble, monomer concentration is 15wt%, crosslinker concentration is 0.5wt%, form monomer premixed liquid, in 100ml monomer premixed liquid, adding particle diameter is the alumina powder jointed 240g of 1 μ m, add the sintering agent calcium fluoride powder 9.6g of aluminum oxide powder body burden 4% and the Suzhou of aluminum oxide powder body burden 5% soil 12g, dispersion agent is ammonium citrate 1g, stirring obtains solid load and is about 40% ceramic size, in above-mentioned slurry, add catalyst n, N, N ', N '-Tetramethyl Ethylene Diamine 25 μ l, then stir, add again initiator 8% ammonium persulfate solution 50 μ l, after stirring, inject at once mould, and will make Multi needle by oneself and become punch die (syringe needle φ=2mm, 4 hole/square centimeters) insert in slurry, the demoulding after slurry is gel, obtain the wet base of honeycomb.The base that will wet is put into 50 DEG C, baking oven and is dried 24 hours, dry base substrate is put into retort furnace (BTF-1700C), be warming up to 1600 DEG C with 10 DEG C/min of speed, organism completes eliminating in temperature-rise period, 1600 DEG C of sintering 2 hours, are had the cellular alumina pottery of " duct inner wall extend whisker " structure.The cellular alumina ceramic-like that the SEM photo of the cellular alumina pottery that the present embodiment prepares and XRD figure and embodiment 1 make seemingly.
This ceramic honey comb aperture is 0.1mm, and void content is 60%.The method specifying according to GB/T1964 detects, and obtaining horizontal ultimate compression strength is 8MPa, axial compression strength 18MPa.Ceramic honey comb is boiled after 0.5 hour and placed after 24 hours again with 10% salpeter solution, and solution is water white transparency, and resist chemical performance is good.After testing, the cellular alumina pottery of preparation has that osmotic pressure is high, geometric jacquard patterning unit surface is large, diffusion length is short, is conducive to counting of particle and discharges with gas and dwindle filtration volume, the excellent specific properties such as the smoothness of fluid.
The above is only the preferred embodiment of the present invention; it should be pointed out that for those skilled in the art, do not departing under the prerequisite of the technology of the present invention principle; can also make some improvements and modifications, these improvements and modifications also should be considered as protection scope of the present invention.
Claims (10)
1. a preparation method for cellular alumina pottery, is characterized in that, described method comprises the following steps:
1) preparation has the cellular alumina base substrate in parallel duct and is dried;
2) dried base substrate is carried out to organic eliminating;
3) Calcined polishing aluminum oxide honeycomb base substrate, obtains body portion particle in conjunction with tight, and hole inner wall extend has the cellular alumina pottery of whisker.
2. preparation method as claimed in claim 1, is characterized in that, the cellular alumina base substrate in step 1) with parallel duct adopts extrusion moulding preparation.
3. preparation method as claimed in claim 1, it is characterized in that, in step 1), cellular alumina base substrate adopts dry pressing, gel casting forming method or direct coagulation casting method first to prepare biscuit, then adopts mechanical hole building method to make to have the cellular alumina base substrate in parallel duct.
4. the method as described in as arbitrary in claim 1～3, is characterized in that, in step 1), taking alumina powder jointed as raw material, and adds sintering agent, dispersion agent, shaping medium to mix, and prepares aluminum oxide base substrate.
5. method as claimed in claim 4, is characterized in that, described alumina powder jointed particle diameter 0.5 μ m～3 μ m, accounts for total powder 65～75wt%.
6. method as claimed in claim 4, is characterized in that, described sintering agent is kaolin, CaCO
3, BaCO
3, MgCO
3, talcum, rhombspar and/or wollastonite, wherein, kaolin content is total powder quality 9～20%, CaCO
3content is 0～3% of total powder quality, BaCO
3content is 0～3% of total powder quality, MgCO
3content is 0～3% of total powder quality, and talc content is total powder quality 0～2%, and rhombspar content is total powder quality 0～9%, and wollastonite content is total powder quality 0～2%.
7. the method as described in as arbitrary in claim 1～3, is characterized in that, in step 1), the drying means of cellular alumina base substrate is that room temperature is dried in the shade or 40 DEG C～60 DEG C oven dry, keeps the parallel construction in honeycomb duct.
8. the method for claim 1, is characterized in that step 2) in dried base substrate is carried out to organism eliminating, temperature is at 500 DEG C～800 DEG C, the time is 0.5～3h.
9. the method for claim 1, is characterized in that, in step 3), calcining temperature is 1580 DEG C～1600 DEG C, insulation 1～3h.
10. require the described preparation-obtained cellular alumina pottery of preparation method according to claim 1.
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