CN105439545A - 耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器及制备方法 - Google Patents
耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器及制备方法 Download PDFInfo
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims abstract description 143
- 239000000919 ceramic Substances 0.000 title claims abstract description 80
- 239000006260 foam Substances 0.000 title claims abstract description 57
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 27
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 26
- 238000002360 preparation method Methods 0.000 title claims description 15
- 238000005260 corrosion Methods 0.000 title abstract 3
- 230000007797 corrosion Effects 0.000 title abstract 3
- 239000000843 powder Substances 0.000 claims abstract description 53
- AYJRCSIUFZENHW-UHFFFAOYSA-L barium carbonate Chemical compound [Ba+2].[O-]C([O-])=O AYJRCSIUFZENHW-UHFFFAOYSA-L 0.000 claims abstract description 28
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims abstract description 18
- 238000000576 coating method Methods 0.000 claims abstract description 18
- 239000011248 coating agent Substances 0.000 claims abstract description 16
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 14
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 14
- 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 abstract description 14
- 239000002904 solvent Substances 0.000 claims abstract description 14
- 238000001035 drying Methods 0.000 claims abstract description 13
- 239000004814 polyurethane Substances 0.000 claims abstract description 13
- 229920002635 polyurethane Polymers 0.000 claims abstract description 13
- 229910052582 BN Inorganic materials 0.000 claims abstract description 12
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims abstract description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 11
- 238000005245 sintering Methods 0.000 claims abstract description 7
- 239000002002 slurry Substances 0.000 claims abstract description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 5
- 238000007598 dipping method Methods 0.000 claims abstract description 5
- 238000011065 in-situ storage Methods 0.000 claims abstract description 4
- 239000011159 matrix material Substances 0.000 claims abstract description 3
- 229910052814 silicon oxide Inorganic materials 0.000 claims abstract description 3
- 239000004411 aluminium Substances 0.000 claims description 23
- 235000015895 biscuits Nutrition 0.000 claims description 20
- 239000007788 liquid Substances 0.000 claims description 18
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 12
- 239000010703 silicon Substances 0.000 claims description 12
- 229910052710 silicon Inorganic materials 0.000 claims description 12
- 239000003795 chemical substances by application Substances 0.000 claims description 10
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- 239000006259 organic additive Substances 0.000 claims description 10
- 238000010792 warming Methods 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 6
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 4
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 claims description 3
- 101710194948 Protein phosphatase PhpP Proteins 0.000 claims description 3
- 238000007654 immersion Methods 0.000 claims description 3
- HWGNBUXHKFFFIH-UHFFFAOYSA-I pentasodium;[oxido(phosphonatooxy)phosphoryl] phosphate Chemical compound [Na+].[Na+].[Na+].[Na+].[Na+].[O-]P([O-])(=O)OP([O-])(=O)OP([O-])([O-])=O HWGNBUXHKFFFIH-UHFFFAOYSA-I 0.000 claims description 3
- 229920001495 poly(sodium acrylate) polymer Polymers 0.000 claims description 3
- 229920000058 polyacrylate Polymers 0.000 claims description 3
- 229910052708 sodium Inorganic materials 0.000 claims description 3
- 239000011734 sodium Substances 0.000 claims description 3
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims description 3
- 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 3
- NNMHYFLPFNGQFZ-UHFFFAOYSA-M sodium polyacrylate Chemical compound [Na+].[O-]C(=O)C=C NNMHYFLPFNGQFZ-UHFFFAOYSA-M 0.000 claims description 3
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 3
- UNXRWKVEANCORM-UHFFFAOYSA-I triphosphate(5-) Chemical compound [O-]P([O-])(=O)OP([O-])(=O)OP([O-])([O-])=O UNXRWKVEANCORM-UHFFFAOYSA-I 0.000 claims description 3
- 239000007767 bonding agent Substances 0.000 claims description 2
- 239000001913 cellulose Substances 0.000 claims description 2
- 229920002678 cellulose Polymers 0.000 claims description 2
- 238000011068 loading method Methods 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 238000003756 stirring Methods 0.000 claims description 2
- 230000003628 erosive effect Effects 0.000 claims 8
- 238000002156 mixing Methods 0.000 abstract description 5
- 229910000838 Al alloy Inorganic materials 0.000 abstract description 3
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 abstract 2
- QVQLCTNNEUAWMS-UHFFFAOYSA-N barium oxide Chemical compound [Ba]=O QVQLCTNNEUAWMS-UHFFFAOYSA-N 0.000 abstract 1
- 229910001864 baryta Inorganic materials 0.000 abstract 1
- 239000011230 binding agent Substances 0.000 abstract 1
- 239000010433 feldspar Substances 0.000 abstract 1
- 238000005266 casting Methods 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000009736 wetting Methods 0.000 description 5
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- 230000003245 working effect Effects 0.000 description 3
- VRAIHTAYLFXSJJ-UHFFFAOYSA-N alumane Chemical compound [AlH3].[AlH3] VRAIHTAYLFXSJJ-UHFFFAOYSA-N 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
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- 239000003595 mist Substances 0.000 description 1
- 210000003205 muscle Anatomy 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 210000002435 tendon Anatomy 0.000 description 1
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Abstract
本发明提出的一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器,所述的氧化铝质泡沫陶瓷过滤器是以聚氨酯海绵为基体,浸渍陶瓷粉体与溶剂配制的料浆,并经烘干、烧结制得;其特征在于:所述的陶瓷粉体由氧化铝粉体、高岭土粉体、碳酸钡粉体或硫酸钡粉体混合而成;所述的溶剂包括有水和硅溶胶;所述氧化铝粉体、高岭土粉体、碳酸钡粉体或硫酸钡粉体与结合剂硅溶胶中的氧化硅原位反应生成不易被铝液浸润的钡长石;所述氧化铝质泡沫陶瓷过滤器上涂覆有一层氮化硼涂料。本发明在铝及铝合金熔液中具有良好的高温稳定性与抗侵蚀性。
Description
技术领域
本发明涉及金属熔液的过滤以及净化,属于无机多孔材料的一种,具体涉及一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器及制备方法,应用在铝及其合金的冶炼与铸造等行业。
背景技术
在铝及其合金的熔炼与浇注过程中,无机夹杂物与缩气孔等缺陷是导致铸件报废的主要原因。夹杂缺陷不仅影响制品外观而且严重降低制品的机械性能与使用寿命,因此,减少无机夹杂物与气孔缺陷是生产高质量铸件的关键。
氧化铝质泡沫陶瓷过滤器,可以通过机械拦截、整流浮渣和深层吸附三种过滤净化机制,减少或消除铸件缺陷,提高合金成品率以及加工性能。
传统的氧化铝质泡沫陶瓷在长期与铝液的接触使用中,容易遭受侵蚀而损毁,尽管可以通过提前更换来解决这个问题,但这势必造成单次铸造量减少,增加停机次数,增大企业的生产成本并造成企业生产效率低下。再者,氧化铝质泡沫陶瓷在与铝液的接触中,往往会因为铝液侵蚀而造成部分孔筋断裂,造成二次夹渣污染,这对于汽车、航天、军工等行业一些高要求、高标准的产品而言,是极其不利的。因此,改进氧化铝质泡沫陶瓷的抗侵蚀性,延长其使用寿命具有重要的意义。
发明内容
本发明的目的在于提供一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器及制备方法,使其能适用汽车、航天、军工等高质量铸件生产的需要,延长氧化铝质泡沫陶瓷的使用寿命,提高相关企业的生产效率。
本发明为完成上述目的采用如下技术方案:
一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器,所述的氧化铝质泡沫陶瓷过滤器是以聚氨酯海绵为基体,浸渍陶瓷粉体与溶剂配制的料浆,并经烘干、烧结制得;所述的陶瓷粉体由氧化铝粉体、高岭土粉体、碳酸钡粉体或硫酸钡粉体混合而成;所述的溶剂包括有水和硅溶胶;所述氧化铝粉体、高岭土粉体、碳酸钡粉体或硫酸钡粉体与结合剂硅溶胶中的氧化硅原位反应生成不易被铝液浸润的钡长石;所述氧化铝质泡沫陶瓷过滤器上涂覆有一层氮化硼涂料。
氧化铝质泡沫陶瓷过滤器的料浆组成及质量百分比为:氧化铝粉体47%~65%,高岭土粉体12%~25%,碳酸钡/硫酸钡粉体3%~8%,水12%~16%,硅溶胶4%~6%,陶瓷粉体即氧化铝粉体、高岭土粉体、碳酸钡/硫酸钡粉体的重量占料浆总量的80%,溶剂即水和硅溶胶的重量占料浆总量的20%;所述的料浆还外加有分散剂和有机助剂;所述分散剂的加入量为料浆总量0.3%~0.5%,所述有机助剂的加入量为料浆总量0.05%~0.1%。
所述的有机助剂为羧甲基纤维素钠或聚阴离子纤维素的一种。
所述的分散剂为聚丙烯酸铵、聚丙烯酸钠、三聚磷酸钠或六偏磷酸钠中的一种。
一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器的制备方法,其具体步骤如下:
1)、按照上述浆料的配比准备陶瓷粉体、溶剂、分散剂和有机助剂;
2)、将分散剂和有机助剂加入到溶剂中混合均匀;将陶瓷粉体边搅拌边加入溶剂中制备成均质料浆;
3)、以聚氨酯海绵为载体,浸渍料浆,并挤出多余料浆得到素坯;
4)、将素坯放入烘箱内干燥,干燥后素坯装窑,升温至1100℃~1200℃高温烧结,得到氧化铝质泡沫陶瓷过滤器;
5)在所制得的氧化铝质泡沫陶瓷过滤器上涂覆氮化硼涂料,进行不沾铝处理。
氮化硼涂料的涂覆方式有两种,当氧化铝泡沫陶瓷尺寸较小、质量较轻时采用浸渍离心法,当其尺寸较大、质量较重时采用喷涂法。
氧化铝质泡沫陶瓷过滤器烧成过程为:以1℃/min升温至600℃低温排塑,再以3℃/min升至1000℃,然后以1℃/min升至1100~1200℃,优选1200℃,并保温2~4h。
素坯的烘干工艺为:在60℃温度下保温12h后,再在110℃温度下保温12h。
本发明提出的一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器及制备方法,在氧化铝质泡沫陶瓷的生产过程中,原料中的物质发生原位反应生成了不易被铝液浸润的钡长石,随后在所得氧化铝质泡沫陶瓷的表面涂覆一层氮化硼涂料,从而得到具有双层防铝液润湿的的氧化铝质泡沫陶瓷过滤器;本发明制备的氧化铝质泡沫陶瓷在铝及铝合金熔液中具有良好的高温稳定性与抗侵蚀性,适用于汽车、航天、军工等领域高质量铸件的生产要求。较之普通氧化铝泡沫陶瓷,其使用的时间也大大提高。
具体实施方式
以下通过实施例对本发明作进一步说明。
实施例1
将陶瓷粉体按下述质量称量:
氧化铝粉体:高岭土微粉:碳酸钡/硫酸钡=470g:250g:80g
在容器中以下述质量配制混合溶液:水140g;硅溶胶60g;聚丙烯酸钠3g;CMC0.5g;边搅拌溶液,边加入上述陶瓷粉体配制成均质料浆;
选用20PPI的聚氨酯海绵,亲水处理后加工成Φ80mm×20mm的圆片,作为陶瓷料浆的载体。
将聚氨酯海绵圆片浸入料浆,充分润湿,采用辊压工艺,挤出多余料浆,制成泡沫陶瓷过滤器素坯;将素坯放入干燥设备内,控制温度60℃×12h、110℃×12h进行烘干处理。
最后,将泡沫陶瓷过滤器素坯放入烧成设备内,以1℃/min升温至600℃低温排塑,再以3℃/min升至1150℃,然后以1℃/min升至1200℃并保温4h。自然冷却到室温出炉,得到的氧化铝质泡沫陶瓷再进行氮化硼涂料涂覆处理。
实施例2
将陶瓷粉体按下述质量称量:
氧化铝粉体:高岭土粉体:碳酸钡/硫酸钡=650g:120g:30g
在容器中以下述质量配制混合溶液:水150g;硅溶胶50g;聚丙烯酸铵4g;CMC0.75g。边搅拌溶液,边加入上述陶瓷粉体配制成均质料浆。
选用20PPI的聚氨酯海绵,亲水处理后加工成Φ80mm×20mm的圆片,作为陶瓷料浆的载体。
将聚氨酯海绵圆片浸入料浆,充分润湿,采用辊压工艺,挤出多余料浆,制成泡沫陶瓷过滤器素坯。将素坯放入干燥设备内,控制温度60℃×12h、110℃×12h进行烘干处理。
最后,将泡沫陶瓷过滤器素坯放入烧成设备内,以1℃/min升温至600℃低温排塑,再以3℃/min升至1150℃,然后以1℃/min升至1200℃并保温2h。自然冷却到室温出炉,得到的氧化铝质泡沫陶瓷再进行氮化硼涂料涂覆处理。
实施例3
将陶瓷粉体按下述质量称量:
氧化铝粉体:高岭土粉体:碳酸钡/硫酸钡=500g:250g:50g
在容器中以下述质量配制混合溶液:水160g;硅溶胶40g;三聚磷酸钠5g;CMC1g;边搅拌溶液,边加入上述陶瓷粉体配制成均质料浆。
选用20PPI的聚氨酯海绵,亲水处理后加工成Φ80mm×20mm的圆片,作为陶瓷料浆的载体。
将聚氨酯海绵圆片浸入料浆,充分润湿,采用辊压工艺,挤出多余料浆,制成泡沫陶瓷过滤器素坯。将素坯放入干燥设备内,控制温度60℃×12h、110℃×12h进行烘干处理。
最后,将泡沫陶瓷过滤器素坯放入烧成设备内,以1℃/min升温至600℃低温排塑,再以3℃/min升至1150℃,然后以1℃/min升至1200℃并保温3h。自然冷却到室温出炉,得到的氧化铝质泡沫陶瓷再进行氮化硼涂料涂覆处理。
实施例4
将陶瓷粉体按下述质量称量:
氧化铝粉体:高岭土粉体:碳酸钡/硫酸钡=510g:230g:60g
在容器中以下述质量配制混合溶液:水155g;硅溶胶45g;六偏磷酸钠3g;PAC0.5g。边搅拌溶液,边加入上述陶瓷粉体配制成均质料浆。
选用20PPI的聚氨酯海绵,亲水处理后加工成Φ80mm×20mm的圆片,作为陶瓷料浆的载体。
将聚氨酯海绵圆片浸入料浆,充分润湿,采用辊压工艺,挤出多余料浆,制成泡沫陶瓷过滤器素坯。将素坯放入干燥设备内,控制温度60℃×12h、110℃×12h进行烘干处理。
最后,将泡沫陶瓷过滤器素坯放入烧成设备内,以1℃/min升温至600℃低温排塑,再以3℃/min升至1150℃,然后以1℃/min升至1200℃并保温4h。自然冷却到室温出炉,得到的氧化铝质泡沫陶瓷再进行氮化硼涂料涂覆处理。
Claims (8)
1.一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器,所述的氧化铝质泡沫陶瓷过滤器是以聚氨酯海绵为基体,浸渍陶瓷粉体与溶剂配制的料浆,并经烘干、烧结制得;其特征在于:所述的陶瓷粉体由氧化铝粉体、高岭土粉体、碳酸钡粉体或硫酸钡粉体混合而成;所述的溶剂包括有水和硅溶胶;所述氧化铝粉体、高岭土粉体、碳酸钡粉体或硫酸钡粉体与结合剂硅溶胶中的氧化硅原位反应生成不易被铝液浸润的钡长石;所述氧化铝质泡沫陶瓷过滤器上涂覆有一层氮化硼涂料。
2.如权利要求1所述的耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器,其特征在于:氧化铝质泡沫陶瓷过滤器的料浆组成及质量百分比为:氧化铝粉体47%~65%,高岭土粉体12%~25%,碳酸钡/硫酸钡粉体3%~8%,水12%~16%,硅溶胶4%~8%,陶瓷粉体即氧化铝粉体、高岭土粉体、碳酸钡/硫酸钡粉体的重量占料浆总量的80%,溶剂即水和硅溶胶的重量占料浆总量的20%;所述的料浆还外加有分散剂和有机助剂;所述分散剂的加入量为料浆总量0.3%~0.5%,所述有机助剂的加入量为料浆总量0.05%~0.1%。
3.如权利要求2所述的耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器,其特征在于:所述的有机助剂为羧甲基纤维素钠CMC或聚阴离子纤维素的一种。
4.如权利要求2所述的耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器,其特征在于:所述的分散剂为聚丙烯酸铵、聚丙烯酸钠、三聚磷酸钠或六偏磷酸钠中的一种。
5.一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器的制备方法,其特征在于:氧化铝质泡沫陶瓷过滤器制备方法的具体步骤如下:
1)、按照上述浆料的配比准备陶瓷粉体、溶剂、分散剂和有机助剂;
2)、将分散剂和有机助剂加入到溶剂中混合均匀;将陶瓷粉体边搅拌边加入溶剂中制备成均质料浆;
3)、以聚氨酯海绵为载体,浸渍料浆,并挤出多余料浆得到素坯;
4)、将素坯放入烘箱内干燥,干燥后素坯装窑,升温至1100℃~1200℃高温烧结,得到氧化铝质泡沫陶瓷过滤器;
5)在所制得的氧化铝质泡沫陶瓷过滤器上涂覆氮化硼涂料,进行不沾铝处理。
6.如权利要求5所述的一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器的制备方法,其特征在于:氮化硼涂料的涂覆方式有两种,当氧化铝泡沫陶瓷尺寸较小、质量较轻时采用浸渍离心法,当其尺寸较大、质量较重时采用喷涂法。
7.如权利要求5所述的一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器的制备方法,其特征在于:氧化铝质泡沫陶瓷过滤器烧成过程为:以1℃/min升温至600℃低温排塑,再以3℃/min升至1000℃,然后以1℃/min升至1100~1200℃,优选1200℃,并保温2~4h。
8.如权利要求5所述的一种耐铝液侵蚀的氧化铝质泡沫陶瓷过滤器的制备方法,其特征在于:素坯的烘干工艺为:在60℃温度下保温12h后,再在110℃温度下保温12h。
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