CN104310971A - 氧化铝复合材料及其制备大口径工业陶瓷阀芯的方法 - Google Patents
氧化铝复合材料及其制备大口径工业陶瓷阀芯的方法 Download PDFInfo
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- 239000002131 composite material Substances 0.000 title claims abstract description 17
- 238000000034 method Methods 0.000 title claims abstract description 15
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 title claims abstract description 12
- 239000002994 raw material Substances 0.000 claims abstract description 10
- 238000005245 sintering Methods 0.000 claims abstract description 10
- 238000000227 grinding Methods 0.000 claims abstract description 6
- 239000000454 talc Substances 0.000 claims abstract description 5
- 235000012222 talc Nutrition 0.000 claims abstract description 5
- 229910052623 talc Inorganic materials 0.000 claims abstract description 5
- 238000000498 ball milling Methods 0.000 claims abstract description 4
- 229910000420 cerium oxide Inorganic materials 0.000 claims abstract description 4
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 claims abstract description 4
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 claims abstract description 4
- 239000004033 plastic Substances 0.000 claims abstract description 4
- 229920003023 plastic Polymers 0.000 claims abstract description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 15
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 13
- 238000009413 insulation Methods 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 8
- 238000007493 shaping process Methods 0.000 claims description 7
- 238000003756 stirring Methods 0.000 claims description 7
- AYJRCSIUFZENHW-UHFFFAOYSA-L barium carbonate Chemical compound [Ba+2].[O-]C([O-])=O AYJRCSIUFZENHW-UHFFFAOYSA-L 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 6
- 239000005995 Aluminium silicate Substances 0.000 claims description 5
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- 235000012211 aluminium silicate Nutrition 0.000 claims description 5
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 5
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- IXPNQXFRVYWDDI-UHFFFAOYSA-N 1-methyl-2,4-dioxo-1,3-diazinane-5-carboximidamide Chemical compound CN1CC(C(N)=N)C(=O)NC1=O IXPNQXFRVYWDDI-UHFFFAOYSA-N 0.000 claims description 2
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- 235000010413 sodium alginate Nutrition 0.000 claims description 2
- 229940005550 sodium alginate Drugs 0.000 claims description 2
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims description 2
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims description 2
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 2
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- 239000000956 alloy Substances 0.000 abstract 1
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- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
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Abstract
本发明公开了一种氧化铝复合材料，由以下重量份的原料组成：氧化铝60-85，氧化锆15-40，高岭土2-5，滑石1-2，碳酸钡0.5-1，所述氧化锆含有氧化钇2.5-3.5，氧化铈1.5-2.5。其制备大口径工业陶瓷阀芯的方法：将原料用搅拌磨超细球磨至平均粒径小于0.4μm，并加入分散剂和增塑剂制成流动性以及可塑性良好的浆料，采用多孔塑料或高强石膏模具高压注浆成型；高温烧结成陶瓷坯体；然后采用金刚石磨具将陶瓷毛坯磨削成表面光洁的成品陶瓷。本发明制作工艺可靠，原料成本低；制得的陶瓷阀芯使用温度高，耐磨损、耐冲刷、耐腐蚀性好；使用寿命较硬质合金可以提高5-10倍。
Description
技术领域
本发明涉及一种特种陶瓷材料，具体涉及氧化铝复合材料及其制备大口径工业陶瓷阀芯的方法。
背景技术
大口径工业陶瓷阀门主要用于电厂干灰系统、电解铝以及选矿设备，大口径工业陶瓷阀芯是大口径工业陶瓷阀门的密封配件。由于这些使用场合工况通常比较恶劣，冲刷、腐蚀、磨损比较厉害，一般的金属部件很难承受这种工况，阀芯表面易被腐蚀变形，影响阀门的开合，严重时，甚至出现裂纹等，降低阀门使用寿命。陶瓷因其独特的坚固性和耐腐蚀性成为制作阀芯的理想材质，陶瓷阀芯已经广泛应用在家用水阀等领域。目前，用于制作工艺的限制，工业用大口径阀芯大部分仍为硬质合金，一般的陶瓷成型工艺只能生产口径Φ500陶瓷件。
发明内容
本发明的目的就在于克服现有的技术不足，提供一种由氧化铝复合材料制备大口径工业陶瓷阀芯的方法，生产的工业陶瓷阀芯耐冲刷耐腐蚀耐磨损，且生产成本低，生产工艺可靠。
本发明的技术方案如下：
一种氧化铝复合材料，由以下重量份的原料组成：氧化铝60-85，氧化锆15-40，高岭土2-5，滑石1-2，碳酸钡0.5-1，所述氧化锆含有氧化钇2.5-3.5，氧化铈1.5-2.5。
所述的氧化铝复合材料制备大口径工业陶瓷阀芯的方法，包括制浆、成型、烧成步骤：①制浆：按配方量称取原料，加入纯水20-30重量份，再加入0.5-1重量份的分散剂，放入高速搅拌磨中，搅拌球磨至物料粒径为0.3-0.5μm，再加入3-5重量份的增塑剂，搅拌15分钟左右；料浆出磨静置7-10天；②成型：将模具用夹具夹好，采用高压高位槽将制好的料浆灌注至模具中脱水凝固成型，成型的坯体在湿度70-95％、温度15-35℃的环境干燥7-10天，得到陶瓷生坯；③烧成：对陶瓷生坯进行高温烧结，烧成曲线是：室温-500℃，15-20小时均匀升温，500℃保温2-3小时；500-1300℃，15-20小时均匀升温，1300℃保温2-3小时；1300-1550℃，5-8小时均匀升温，1550℃保温2-3小时；1550-1650℃，5-8小时均匀升温，1650℃保温2-4小时；1650-室温，自然降温。
所述的分散剂为9300、六偏磷酸钠或海藻酸钠，所述的增塑剂为1788、或羧甲基纤维素，所述的模具为高强石膏模具或多孔塑料模具。
在烧成步骤后，用磨具将烧成的陶瓷阀芯打磨为表面光洁的成品。
相对于现有技术，本发明在氧化铝粉末中引入稳定氧化锆，并添加适当的助烧剂，使得到的氧化锆复合氧化铝材料具有高韧性，并且耐冲刷耐腐蚀耐磨损。配方大量使用了价格低廉的氧化铝，添加少量的稀土氧化物及高岭土成分，相比较其他陶瓷阀芯材料，还具有原料成本低的优点。
采用上述材料制备Φ500-Φ1000大口径工业陶瓷阀芯的方法，操作方便，可控性高，后期磨削工作量大大减小，工艺简单可靠。所制得的大口径工业陶瓷阀芯使用温度高，耐磨损、耐冲刷、耐腐蚀性好，使用寿命较硬质合金可以提高5-10倍。拓宽了阀门的使用范围，降低了阀门的维修更换次数，提高了配套设备系统运行的安全性和稳定性。
具体实施方式
实施例1：
按配方称量氧化铝70公斤，含有3公斤氧化钇、2公斤氧化铈的稳定氧化锆25公斤，淘洗高岭土2公斤，烧滑石2公斤，工业纯碳酸钡1公斤，将称好的原材料按氧化铝、碳酸钡、烧滑石、高岭土、稳定氧化锆的顺序加入带循环泵的搅拌磨中，倒入混好1公斤9300的高纯水25公斤；搅拌球磨7个小时左右，待浆料平均粒径检测值为0.4微米时，加入5公斤增塑剂1788，继续搅拌15分钟出磨静置7天，使物料与有机物充分渗透陈腐均匀，制备出固含量为80wt％以上流动性良好的浆料；将按图纸加工好的高强石膏或多孔塑料模具用夹具夹好，采用高压高位槽将制好的料浆灌注至磨具中脱水凝固成型，成型的坯体经过湿度80％，温度25℃的环境干燥7天，得到陶瓷生坯；对陶瓷生坯进行高温烧结，所述的烧成曲线是：室温－500℃，15小时均匀升温排胶，500℃保温2小时；500－1300℃，15小时均匀升温晶型转化，1300℃保温2小时；1300-1550℃，5小时均匀升温烧结，1550℃保温2小时；1550-1650℃，5小时均匀升温晶粒处理，1650℃保温2小时；1650－室温，自然冷却至室温；然后采用金刚石磨具将陶瓷毛坯磨削成表面光洁的成品陶瓷阀芯。
其余实施例氧化铝复合材料原料配方如表1所示，并且按照实施例1的制备方法进行大口径工业陶瓷阀芯，具体工艺参数见表1：
在表1中，升温Ⅰ表示室温-500℃，保温Ⅰ表示500℃；升温Ⅱ表示500-1300℃，保温Ⅱ表示1300℃；升温Ⅲ表示1300-1550℃，保温Ⅲ表示1550℃；升温Ⅳ表示1550-1650℃，保温Ⅳ表示1650℃。
本发明制作工艺可靠，原料成本低；在特种陶瓷配方中通过在氧化铝粉体中引入适当起相变增韧作用的添加剂稳定氧化锆，以及适当的助烧剂，使得材料具有很细的(≤1μm)晶粒构造，很高的韧性、耐磨性、耐冲刷性、耐腐蚀性；最后经过精细的磨削加工，制得的陶瓷阀芯使用温度高，耐磨损、耐冲刷、耐腐蚀性好；使用寿命较硬质合金可以提高5-10倍。
以上所述的仅是本发明的优选实施方式，应当指出，对于本领域的技术人员来说，在不脱离本发明整体构思前提下，还可以作出若干改变和改进，这些也应该视为本发明的保护范围，这些都不会影响本发明实施的效果和专利的实用性。
Claims (4)
1.一种氧化铝复合材料，其特征在于由以下重量份的原料组成：氧化铝60-85，氧化锆15-40，高岭土2-5，滑石1-2，碳酸钡0.5-1，所述氧化锆含有氧化钇2.5-3.5，氧化铈1.5-2.5。
2.如权利要求1所述的氧化铝复合材料制备大口径工业陶瓷阀芯的方法，包括制浆、成型、烧成步骤，其特征在于： ①制浆：按配方量称取原料，加入纯水20-30 重量份，再加入0.5-1重量份的分散剂，放入高速搅拌磨中，搅拌球磨至物料粒径为0.3-0.5μm，再加入3-5重量份的增塑剂，搅拌15分钟左右；料浆出磨静置7-10天； ②成型：将模具用夹具夹好，采用高压高位槽将制好的料浆灌注至模具中脱水凝固成型，成型的坯体在湿度70-95%、温度15-35℃的环境干燥7-10天，得到陶瓷生坯； ③烧成：对陶瓷生坯进行高温烧结，烧成曲线是：室温-500℃，15-20小时均匀升温，500℃保温2-3小时；500-1300℃，15-20小时均匀升温，1300℃保温2-3小时；1300-1550℃，5-8小时均匀升温，1550℃保温2-3小时；1550-1650℃，5-8小时均匀升温，1650℃保温2-4小时；1650-室温，自然降温。
3.如权利要求2所述的氧化铝复合材料制备大口径工业陶瓷阀芯的方法，其特征在于；所述的分散剂为9300、六偏磷酸钠或海藻酸钠，所述的增塑剂为1788、或羧甲基纤维素，所述的模具为高强石膏模具或多孔塑料模具。
4.如权利要求2所述的氧化铝复合材料制备大口径工业陶瓷阀芯的方法，其特征在于：在烧成步骤后，用磨具将烧成的陶瓷阀芯打磨为表面光洁的成品。
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