CN105541306B - A kind of aluminium oxide closed cell foamed ceramics and preparation method thereof of alumina fibre enhancing - Google Patents
A kind of aluminium oxide closed cell foamed ceramics and preparation method thereof of alumina fibre enhancing Download PDFInfo
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Abstract
The invention discloses a kind of aluminium oxide closed cell foamed ceramics and preparation method thereof of alumina fibre enhancing, temperature in use<1700 DEG C, compression strength be 7MPa ~ 10MPa, in 1600 DEG C × for 24 hours under the permanent linear shrinkage of heating<1.5%, 1000 DEG C of hot face thermal coefficients are 0.40 ~ 0.60W/m K, and bulk density is 0.7 ~ 1.0g/cm3, the porosity is 75 ~ 83%;Al in chemical composition2O3The principal crystalline phase of content >=95wt%, foamed ceramics is α Al2O3, Micro Phases further include Ludox and α Al2O3The mullite that pyroreaction generates.The present invention is using addition pore creating material in such a way that foaming is combined, and the foamed ceramics of preparation is hole-closing structure, and the porosity is high and mechanical property is good, can be used as fire-resistant heat insulating material, is applied to the fields such as high-temperature electric resistance furnace liner, construction material.
Description
Technical field
The invention belongs to foamed ceramics technical fields, and in particular to a kind of aluminium oxide closed-cell foam of alumina fibre enhancing
Ceramics and preparation method thereof.
Background technology
Foamed ceramics can be divided into closed cell foamed ceramics and open celled foam ceramics by relationship between hole.Alumina Foam Ceramics
Since with high specific surface area, complicated pore distribution, pore size is controllable, while having good chemical stability, heat
It the advantages that stability and higher mechanical strength, applied to melted metal filtering, catalyst carrier, heat preserving and insulating material and builds
Build the fields such as material.According to the difference of its application, also there is corresponding preparation method.
Polyurethane sea is utilized in the paper " polyurethane template low temperature preparation Alumina Foam Ceramics filter " delivered
Continuous oxide impregnation aluminium powder and slurry made of aluminium dihydrogen phosphate, obtain hanging biscuit, alumina bubble are prepared for through 800 DEG C of pyrolysis
Foam ceramic filter.The bulk density of foamed ceramics is 1.21 g/cm3, flexural strength reaches as high as 4.55MPa.Using having
The pore size and structure of the obtained porous ceramic film material of machine foam impregnation method depend entirely on the hole ruler of the organic foam of selection
Very little and structure, it is also related with coated in the slurry thickness in eyed structure.It is higher and for trepanning that this method can prepare porosity
Foamed ceramics, but the mechanical property of product is poor, and organic matter loss on ignition is very big.
Addition pore creating material method is that the pore creating material for occupying certain space volume is added before the preparation of preform blank.Follow-up
Sintering process in, the pore creating material of low ignition point is sintered vaporization and leaves matrix, to be gone in green body into certain hole, realizes
The preparation of foamed ceramics.The shape and distribution of the shape of stomata and distribution depending on pore creating material, advantage are in foamed ceramics
Foamed material complex-shaped, that stomata is different can be obtained, shortcoming is that the distributing homogeneity of stomata is bad.Patent No. CN
103787691A is disclosed using the blend of water and pentamethylene as pore creating material, is cured by the polymerisation of polyethers, then through trepanning
It handles, Alumina Foam Ceramics is made after high temperature sintering.The disadvantage is that need additional trepanning processing, and will in oxy-acetylene environment,
Increase operation difficulty.
When foamed ceramics is as heat preserving and insulating material, in order to keep its thermal conductivity lower, foamed ceramics is needed to have higher
It holds one's breath porosity.Foaming is suitable for the preparation of high porosity ceramic material of holding one's breath, and the foamed ceramics porosity prepared is big, intensity
It is high.Patent No. CN 104311118A disclose the addition polysaccharide organic foaming agent and sintering aid etc. in ceramic powder,
It after 120 ~ 180 DEG C of foamed solidifications, is burnt into and ultralight Alumina Foam Ceramics is made, the disadvantage is that addition polyoses content is high, blowing temperature
It is high.In addition, also easily there is dusting peeling phenomenon during preparing porous ceramics in foaming.
Invention content
The object of the present invention is to provide a kind of aluminium oxide closed cell foamed ceramics and preparation method thereof of alumina fibre enhancing,
The foamed ceramics performance being prepared is stablized, and density is small, intensity is high.
To achieve the goals above, the technical solution adopted in the present invention is:A kind of aluminium oxide of alumina fibre enhancing
Closed cell foamed ceramics, temperature in use<1700 DEG C, compression strength be 7MPa ~ 10MPa, heat permanent linear shrinkage (1600 DEG C ×
24h)<1.5%, 1000 DEG C of hot face thermal coefficients are 0.40 ~ 0.60W/m K, and bulk density is 0.7 ~ 1.0g/cm3, the porosity is
75~83%;Al in chemical composition2O3Content >=95wt%, the principal crystalline phase of foamed ceramics are the α-Al of matrix and reinforcement2O3, micro
It further include mutually the mullite etc. that Ludox is generated with matrix and reinforcement pyroreaction.
A kind of aluminium oxide closed cell foamed ceramics and preparation method thereof of alumina fibre enhancing, include the following steps:
(1)Prepare ceramic slurry
By weight ratio, alumina short fibre 10 ~ 30wt%, α-Al are taken2O355 ~ 75wt% of powder, pore creating material 1 ~ 2%, rheology
0 ~ 1wt% of agent, 5 ~ 15wt% of binder, 2 ~ 3wt% of sintering aid are sufficiently mixed stirring, obtain the slurry with certain rheological properties energy
Material;
(2)Make ceramic green
After the foaming agent of 2 ~ 5wt% is added in slurry after thorough mix-ing, 20 ~ 40s of heating stirring at 70 ~ 80 DEG C, until
Slurry foams, and before slurry is not generated and caved in, injects in preforming non-porous mold, obtains wet base, and shifted together with mold
To 0.5 ~ 1h is conserved in climatic chamber at 70 ~ 75 DEG C, green body curing and demolding is waited for, then be placed in blast dry oven in 80
Dry 4 ~ 5h, obtains green compact at ~ 90 DEG C;
(3)High temperature sintering shapes
Green compact are placed in Muffle furnace, are warming up to 900 ± 50 DEG C from 100 ± 10 DEG C with the heating rate of 3 DEG C/min, heat preservation
50~70min;It is warming up to 1600 ~ 1650 DEG C from 900 ± 50 DEG C with 5 DEG C/min again, and keeps the temperature 100 ~ 120min, after furnace cooling
Machined processing obtains aluminium oxide closed cell foamed ceramics.
Step(1)In, the pore creating material is or mixtures thereof one kind in calcium sulfate or graphite powder, and rheological agent is carboxymethyl
Cellulose, in binder, low temperature bonding agent is polyacrylamide, high-temperature agglomerant be Ludox or one kind in Aluminum sol or its
Mixture, sintering aid are or mixtures thereof one kind in kaolin or bentonite.
Further, the preparation process of Aluminum sol is as follows:By anhydrous AlCl3Water is dissolved in Al micro mists according to molar ratio 1:5,
It is placed in reaction kettle, at 90 ~ 100 DEG C after 2 ~ 3h of back flow reaction, Aluminum sol is obtained by filtration.
Further, the preparation process of Ludox is as follows:Ethyl orthosilicate (TEOS) and absolute ethyl alcohol (EtOH) is taken to mix
As A liquid;Concentrated nitric acid (HNO is added in distilled water3) and glacial acetic acid (HAc) be used as B liquid;A liquid is slowly injected into B liquid while stirring
In, after standing 0.5 ~ 1h, as Ludox, wherein the volume ratio of each reactant is TEOS:ETOH:HNO3:HAc=2.5:1:
0.3:0.3。
Step(1)In, the preparation process of alumina short fibre is as follows:Alumina gel fiber is placed in Muffle furnace, with 2
DEG C/min is warming up to 500 DEG C from 100 DEG C, and keeps the temperature 0.5 ~ 1h, the staple fiber for forming 3 ~ 5mm is crushed after furnace cooling.
Step(2)In, foaming agent is or mixtures thereof one kind of hydrogen peroxide or calcium carbonate.
Compared with prior art, it is an advantage of the invention that:
(1)Using alumina fibre as reinforcement, using the extraction of fiber, bridging, crack deflection etc. enhances mechanism, carries
The high fracture toughness of foamed ceramics matrix.
(2)The substances such as Ludox and matrix On In-situ Synthesis of Mullite Whisker etc. at high temperature, improve the strong of foamed ceramics
Degree plays the role of further toughening, while some glass that high temperature is formed mutually can efficiently reduce the scaling-off of foamed ceramics
And dusting.
(3)Using foaming in such a way that pore creating material method is combined, Minute pores obtained are evenly distributed, and are not reducing pottery
In the case of porcelain compression strength, its porosity is further increased, and then improve the thermal and insulating performance of foamed ceramics.
Description of the drawings
Fig. 1 is the pictorial diagram of the aluminium oxide closed cell foamed ceramics of alumina fibre enhancing of the present invention.
Specific implementation mode
The present invention is further described below in conjunction with the accompanying drawings.
Embodiment 1:
Ethyl alcohol (EtOH) mixing of the ethyl orthosilicate (TEOS) and 20ml of 50ml is taken to be used as A liquid;It is added in the water of 50ml
Concentrated nitric acid (the HNO of 6ml3) and 6ml glacial acetic acid (HAc) be used as B liquid;A liquid is slowly injected into while stirring in B liquid, stands 0.5
After ~ 1h, as Ludox, the Ludox particle size analysis that is prepared is small, diameter narrowly distributing, and performance is stablized, can preserve 20h with
On.
Alumina gel fiber is put into Muffle furnace, 500 DEG C are warming up to from 100 DEG C with the heating rate of 2 DEG C/min, and
0.5 ~ 1h is kept the temperature, makes gelatinous fibre carbonization, the staple fiber of 3 ~ 5mm is broken into after furnace cooling.
Take 30wt% alumina short fibres and the α-Al of 55wt%2O3Graphite powder 2.0wt%, carboxymethyl cellulose is added in powder
1.0wt%, polyacrylamide 1.0wt%, kaolin 2.0wt%, Ludox 6.0% and appropriate distilled water, are sufficiently mixed stirring, obtain
Slurry with certain rheological properties energy.After adding the calcium carbonate of 3.0wt%, 70 DEG C of heating stirring 30s, acidic silicasol and carbon
Sour calcium reaction, slurry foaming, volume expansion.
Before foam collapse, above-mentioned slurry is injected in preforming non-porous mold, obtains wet base, and turn together with mold
It moves to foam after maintenance 0.5h at 70 DEG C in climatic chamber and finish.It waits for green body curing and demolding, places into forced air drying baking
85 DEG C of dry 5h, obtain green compact in case.Green compact are warming up to 900 DEG C from 100 DEG C with 3 DEG C/min, keep the temperature 60min, then with 5 DEG C/min
1600 DEG C are warming up to, and keeps the temperature 120min, then with stove natural cooling.Purpose is volatilized caused by cold stage organic matter
Property gas slowly escaped from ceramic matrix, formed pumiceous texture.Ceramic matrix is set not produced because internal stress is excessive simultaneously
The defects of raw micro-crack, it ensure that the intensity of foamed ceramics.After machined processing, aluminium oxide closed cell foamed ceramics are obtained, such as
Shown in Fig. 1.
The Ludox prepared at present mostly uses the alkaline reagents Hydrolyze methods such as addition ammonium hydroxide.The disadvantage is that ammonium hydroxide volatilization will produce very
Strong irritation, the particle size analysis secondly prepared is big, easily reunites, and the holding time is short.If the heating rate of sintering process is excessively high
Cracking, the deformation that can lead to material reduce the performance of product, and consume if the too low densification process that can slow down between crystal grain
Electricity increases.It is more reasonable using the sintering process in the present embodiment by test of many times.
Use the aluminium oxide closed cell foamed ceramics principal crystalline phase that alumina fibre made from above-mentioned preparation method enhances for aluminium oxide fibre
α-the Al of peacekeeping matrix2O3, the volatilization completely at high temperature such as organic matter, mainly contain in sample element be aluminium, oxygen, silicon and other
Some trace elements.The bulk density of the Alumina Foam Ceramics is about 0.75g/cm3, the porosity is about 83%.1000 DEG C of hot faces
Thermal coefficient is about 0.42W/m K, and it is about 1.3% to heat permanent linear shrinkage (1600 DEG C × for 24 hours), and compression strength is about 7.6MPa.
Embodiment 2:
30g anhydrous Aluminum chlorides are dissolved in 500ml water, are then put into reaction kettle with 30.3g aluminium micro mists, 90 ~ 100 DEG C add
Heat 2 ~ 3h of reflux, is obtained by filtration Aluminum sol(Al2O3Mass fraction be about 12.1%).Its zeta potential value is about 35mV, can stablize guarantor
It deposits to 3d or more.
Take 20wt% alumina short fibres and the α-Al of 60wt%2O3Calcium sulphate dihydrate 2.0wt%, carboxymethyl is added in powder
Cellulose 1.0wt%, polyacrylamide 1.0wt%, Aluminum sol 8wt%, bentonite 3.0wt%.It is added after appropriate distilled water fully mixed
Stirring is closed, the slurry with certain rheological properties energy is obtained.After adding the hydrogenperoxide steam generator of 5.0wt%, 70 DEG C of heating stirrings
40s, until slurry foams.
Before foam collapse, above-mentioned slurry is injected in preforming non-porous mold, obtains wet base, and turn together with mold
It moves to foam after maintenance 1.0h at 75 DEG C in climatic chamber and finish.It waits for green body curing and demolding, places into forced air drying baking
90 DEG C of dry 4h, obtain green compact in case.Green compact are warming up to 850 DEG C from 100 DEG C with 3 DEG C/min, keep the temperature 70min, then with 5 DEG C/min
Heating rate be warming up to 1650 DEG C from 850 DEG C, and 100min is kept the temperature, then with stove natural cooling.After machined processing, obtain
To aluminium oxide closed cell foamed ceramics.
Aluminum sol is prepared instead of hydrolysis of alkoxide using the inorganic salts of aluminium, preparation time is short, method is simple, raw material is cheap.It is logical
Control stoichiometric ratio, heating temperature and heating time are spent, the Aluminum sol that availability can be stablized.
The bulk density of the Alumina Foam Ceramics enhanced using alumina fibre made from above-mentioned preparation method is about 0.80g/
cm3, the porosity is about 80%, and 1000 DEG C of hot face thermal coefficients are about 0.48 W/m k, heat permanent linear shrinkage (1600 DEG C ×
It is about for 24 hours) 1.2%, compression strength is about 8.1MPa.
Embodiment 3:
Take 15wt% alumina short fibres and the α-Al of 65wt%2O3Powder, and calcium sulphate dihydrate 2.0wt% is added, poly- third
It is sufficiently mixed stirring after acrylamide 1.0wt%, Aluminum sol 5.0wt%, Ludox 6.0%, bentonite 3.0wt% and appropriate distilled water,
Obtain the slurry with certain rheological properties energy.After adding 3.0% calcium carbonate, 70 DEG C of heating stirring 20s, acidic silicasol with
Calcium carbonate reaction, slurry foaming generate volume expansion.
Before foam collapse, above-mentioned slurry is injected in preforming non-porous mold, obtains wet base, and turn together with mold
It moves to foam after maintenance 0.5h at 75 DEG C in climatic chamber and finish.It waits for green body curing and demolding, places into forced air drying baking
80 DEG C of dry 4.5h, obtain green compact in case.Green compact are warming up to 950 DEG C from 100 DEG C with 3 DEG C/min, keep the temperature 50min, then with 5 DEG C/
Min to 1600 DEG C, and 120min is kept the temperature, then with stove natural cooling.After through processing, aluminium oxide closed-cell foam pottery is obtained
Porcelain.
The bulk density of the Alumina Foam Ceramics enhanced using alumina fibre made from above-mentioned preparation method is about 0.90g/
cm3, the porosity is about 78%.1000 DEG C of hot face thermal coefficients are about 0.54W/m K, heat permanent linear shrinkage (1600 DEG C × for 24 hours)
About 1.1%, compression strength is about 8.9MPa.
Embodiment 4:
Take 10wt% alumina short fibres and the α-Al of 75wt%2O3Graphite powder 2.0wt%, carboxymethyl cellulose is added in powder
1.0wt%, polyacrylamide 0.5wt%, Aluminum sol 4.5wt%, kaolin 2.0wt% and appropriate distilled water, are sufficiently mixed stirring, obtain
To the slurry with certain rheological properties energy.Add the hydrogenperoxide steam generator of 5wt%(H2O2Content is 30%)Afterwards, 80 DEG C of heating are stirred
Mix 20s, slurry foaming, volume expansion.
Before foam collapse, above-mentioned slurry is injected in preforming non-porous mold, obtains wet base, and turn together with mold
It moves to foam after maintenance 1.0h at 75 DEG C in climatic chamber and finish.It waits for green body curing and demolding, places into forced air drying baking
85 DEG C of dry 4.5h, obtain green compact in case.Green compact are warming up to 900 DEG C from 100 DEG C with the heating rate of 3 DEG C/min, heat preservation
50min, then 1600 DEG C are warming up to 5 DEG C/min, and 120min is kept the temperature, with stove natural cooling.After machined processing, oxygen is obtained
Change aluminium closed cell foamed ceramics.
The bulk density of the Alumina Foam Ceramics enhanced using alumina fibre made from above-mentioned preparation method is about 1.0g/
cm3, the porosity is about 75%.1000 DEG C of hot face thermal coefficients are about 0.59W/m K, heat permanent linear shrinkage (1600 DEG C × for 24 hours)
About 1.0%, compression strength is about 9.9MPa.
Comparative example 1:
Alumina short fibre is not added in comparative example 1, other implementation processes are the same as embodiment 1.Obtained Alumina Foam pottery
The bulk density of porcelain is about 1.3g/cm3, the porosity is about 67%.1000 DEG C of hot face thermal coefficients are about 0.67W/m K, and heating is forever
Linear shrinkage long (1600 DEG C × for 24 hours) and it is about 0.73%, compression strength is about 6.1MPa.
Comparative example 2:
Commercial alumina staple fiber of the addition after 1200 DEG C of firings replaces the aluminium oxide in embodiment 1 short in comparative example 2
Fiber, other implementation processes are the same as embodiment 1.The bulk density of obtained Alumina Foam Ceramics is about 1.1g/cm3, the porosity
About 70%.1000 DEG C of hot face thermal coefficients are about 0.63W/m K, and it is about 0.88% to heat permanent linear shrinkage (1600 DEG C × for 24 hours),
Compression strength is about 7.2MPa.
Comparative example 3:
Foaming agent is not added in comparative example 3, other implementation processes are the same as embodiment 2.The body of obtained Alumina Foam Ceramics
Product density is about 2.1g/cm3, the porosity is about 53%.1000 DEG C of hot face thermal coefficients are about 0.74W/m K, and heating permanent line is received
Contracting (1600 DEG C × for 24 hours) and it is about 0.69%, compression strength is about 8.4MPa.
Comparative example 4:
Sintering aid and high-temperature agglomerant are not added in comparative example 4, other implementation processes are the same as embodiment 1.Obtained oxidation
The bulk density of aluminum foam ceramics is about 0.66g/cm3, the porosity is about 86%.1000 DEG C of hot face thermal coefficients are about 0.38W/
M K, it is about 0.9% to heat permanent linear shrinkage (1600 DEG C × for 24 hours), and compression strength is about 3.5MPa.
By comparing it can be found that can not only improve the porosity of foamed ceramics using carbonization alumina fibre, may be used also
Play the role of reinforcement to matrix using mechanism such as the extraction of fiber, unsticking, bridgings.Compared to single pore creating material method is used, adopt
It is combined with foaming with pore creating material method, can further improve its porosity.Addition sintering aid and high-temperature agglomerant can drop
Sintering temperature and low, while such as mullite crystal whisker of reaction in-situ generation can reduce the scaling-off and dusting of foamed ceramics at room temperature.
Claims (7)
1. a kind of aluminium oxide closed cell foamed ceramics of alumina fibre enhancing, which is characterized in that 1700 DEG C of its temperature in use < resists
Compressive Strength be 7MPa~10MPa, in 1600 DEG C × for 24 hours under the permanent linear shrinkage < 1.5% of heating, 1000 DEG C of hot face thermal coefficients
For 0.40~0.60W/mK, bulk density is 0.7~1.0g/cm3, the porosity is 75~83%;Al in chemical composition2O3Contain
The principal crystalline phase of amount >=95wt%, foamed ceramics is α-Al2O3, Micro Phases further include Ludox and α-Al2O3What pyroreaction generated
Mullite, the foamed ceramics are prepared by following steps:
(1) ceramic slurry is prepared
By weight ratio, alumina short fibre 10~30wt%, α-Al are taken2O355~75wt% of powder, pore creating material 1~2%, stream
Become 0~1wt% of agent, 5~15wt% of binder, 2~3wt% of sintering aid are sufficiently mixed stirring, obtain with certain rheological properties
Can slurry, in the binder, low temperature bonding agent is polyacrylamide, and high-temperature agglomerant is one in Ludox or Aluminum sol
Or mixtures thereof kind, sintering aid is or mixtures thereof one kind in kaolin or bentonite;
(2) ceramic green is made
After the foaming agent of 2~5wt% is added in slurry after thorough mix-ing, 20~40s of heating stirring at 70~80 DEG C, until
Slurry foams, and before slurry is not generated and caved in, injects in preforming non-porous mold, obtains wet base, and shifted together with mold
To in climatic chamber at 70~75 DEG C conserve 0.5~1h, wait for green body curing and demolding, then be placed in blast dry oven in
Dry 4~5h, obtains green compact at 80~90 DEG C;
(3) high temperature sintering shapes
Green compact are placed in Muffle furnace, 900 ± 50 DEG C are warming up to from 100 ± 10 DEG C with the heating rate of 3 DEG C/min, heat preservation 50~
70min;It is warming up to 1600~1650 DEG C from 900 ± 50 DEG C with 5 DEG C/min again, and keeps the temperature 100~120min, is passed through after furnace cooling
Mechanical process obtains the foamed ceramics.
2. the aluminium oxide closed cell foamed ceramics of alumina fibre enhancing as described in claim 1, which is characterized in that step (1)
In, the pore creating material is or mixtures thereof one kind in calcium sulfate or graphite powder, and rheological agent is carboxymethyl cellulose.
3. the aluminium oxide closed cell foamed ceramics of alumina fibre enhancing as described in claim 1, which is characterized in that Aluminum sol
Preparation process is as follows:By anhydrous AlCl3Water is dissolved in Al micro mists according to molar ratio 1: 5, is placed in reaction kettle, in 90~100 DEG C
After 2~3h of lower back flow reaction, Aluminum sol is obtained by filtration.
4. the aluminium oxide closed cell foamed ceramics of alumina fibre enhancing as described in claim 1, which is characterized in that Ludox
Preparation process is as follows:It takes ethyl orthosilicate and absolute ethyl alcohol to mix and is used as A liquid;Dense HNO is added in distilled water3With glacial acetic acid conduct
B liquid;A liquid is slowly injected into while stirring in B liquid, after standing 0.5~1h, as Ludox, wherein the volume ratio of each reactant
For ethyl orthosilicate: absolute ethyl alcohol: HNO3: glacial acetic acid=2.5: 1: 0.3: 0.3.
5. the aluminium oxide closed cell foamed ceramics of alumina fibre enhancing as described in claim 1, which is characterized in that step (1)
In, the preparation process of alumina short fibre is as follows:Alumina gel fiber is placed in Muffle furnace, is risen from 100 DEG C with 2 DEG C/min
Temperature keeps the temperature 0.5~1h to 500 DEG C, and the staple fiber for forming 3~5mm is crushed after furnace cooling.
6. the aluminium oxide closed cell foamed ceramics of alumina fibre enhancing as described in claim 1, which is characterized in that step (2)
In, foaming agent is or mixtures thereof one kind of hydrogen peroxide or calcium carbonate.
7. the preparation method of the aluminium oxide closed cell foamed ceramics of alumina fibre enhancing described in claim 1.
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