CN105906353A - 一种耐磨耐高温的复合陶瓷材料 - Google Patents
一种耐磨耐高温的复合陶瓷材料 Download PDFInfo
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Abstract
一种耐磨耐高温的复合陶瓷材料,其特征在于所述复合陶瓷材料主要由以下组分按重量比配制而成:Al2O3 85~99份、TiC 1~10份、WO3 1~5份、Y2O3添加剂1~8份、BeO 0.1~0.2份。与现有技术相比,本发明采用特殊的材质替代金属5‑Cr25Ni20Si2和Co22作为耐热滑块在加热炉上应用,表现出了耐磨损、耐高温、抗氧化、能抵抗机械载负荷和滑动摩擦和抗热震性能好的优良性能,并且还能够消除“黑印”,提高轧钢成品率,降低了滑块使用成本;在Al2O3复合陶瓷添加了TiC、WO3、Y2O3、BeOY2O3,使Al2O3复合陶瓷材料的性能大幅度提高,使材料具有更好的抗热震稳定性、韧性,特别是耐压强度和高温抗折强度大幅度提升。
Description
技术领域
本发明属于复合结构陶瓷制备方法及这一技术领域,特别属于一种耐磨耐高温的复合陶瓷材料及其制备方法这一技术领域。
背景技术
由于现代社会的发展,国防、汽车、造船等工业用大型宽厚板的需求增加,轧钢加热炉是钢铁企业轧钢生产及产品加工的重要设备,而加热炉滑块作为轧钢加热炉的关键部件,长期处于高温、高磨损、氧化、腐蚀等恶劣工况,因此对加热炉滑块的材质和结构要求比较严格。
轧钢加热炉通常使用 高炉、焦炉混合煤气做为燃料,加热炉内设有若干个水冷管横梁,采用无缝钢管制作, 梁上面镶嵌有间隔布置的金属耐热滑块。通常使用的金属耐热滑块材料为5-Cr25Ni20Si2和Co22。加热时,因为炉内温度为1250-1350℃,金属耐热滑块直接与水冷管连接,环境非常恶劣,导致各种不良问题产生。具体来说,主要表现为:
一、传统的加热炉滑块一般都是金属材质,因为金属耐热滑块的导热系数高,一般为40~60W/m.K,高温钢坯与金属耐热滑块接触部分温度比其它部分低而形成“黑印”,这种水印导致钢坯温度不均匀,局部硬度高,进轧制机进行轧制时,容易产生尺寸偏差和内部缺陷,使废品率升高。
二、传统的加热炉滑块在1300℃的高温使用温度下,金属材料在长期工作后,抗蠕变强度降低,同时抗氧化和抗侵蚀性能也会降低,使用寿命大大下降。
三、传统的加热炉滑块,使用使用Ni和Co的合金,一般为进口材料,成本比较高。
虽然现有技术已经对传统加热炉滑块进行了改进,如在上下合金滑块之间涂覆耐高温绝热涂料,但是此方案“黑印”改善不明显、并且继承了传统加热炉滑块所有缺陷。也有采用金属复合陶瓷(公开号:CN101063187A)、乃至赛龙复合陶瓷(公开号:CN1951872A)作为加热炉滑块的,但由于陶瓷原料选择的不合理以及工艺落后,依然存在普通复合陶瓷耐压强度、热态抗弯强度不高,在长期工作后抗氧化和抗侵蚀性能降低,使用寿命短等问题;此外,合金复合陶瓷滑块还存在导热系数高等诸多问题。
发明内容
本发明所要解决传统的加热炉滑块成本高、导热系数高、抗蠕变强度低,抗氧化和抗侵蚀性能低等技术问题。本发明所要解决的另一个技术问题是普通复合陶瓷耐压强度、热态抗弯强度不高,长期工作后抗氧化和抗侵蚀性能降低。
本发明解决技术问题的技术方案是:一种耐磨耐高温的复合陶瓷材料,其特征在于所述复合陶瓷材料主要由以下组分按重量比配制而成:Al2O3 85~99份、TiC 1~10份、WO3 1~5份、Y2O3添加剂1~8份、BeO 0.1~0.2份。
作为优选,所述复合陶瓷主要由以下陶瓷粉料按重量比烧结而成:Al2O3 93~97份、TiC6~10份、WO3 1~2份、亚纳米级Y2O3添加剂 4~7份、BeO 0.1~0.2份、ZrB20.1~0.2份、TiN0.1~0.2份。
作为优选,所述复合陶瓷材料的生产工艺为:A.精确称量各组分,将各组分依次装入球磨机,加入陶瓷粉料总重量0.9~1.2倍重量的液态湿混剂,球磨直至粉料直径为2~4um后,将料浆进行真空干燥去除液态湿混剂,得到粉料,将粉料破碎、过筛,保存备用;
B.将制好的粉料装入滑块上层的模具中,采用等静压加压成型,其压力为150~180MPa,对成型后的陶瓷件进行粗加工,加工后的半成品放入高温炉中进行烧结,使用中性的充氮气保护进行烧结,从室温逐渐升温1580℃保温烧成,然后随炉冷却,即得成品。
作为优选,所述液态湿混剂为无水乙醇、无水甲醇中的一种。
作为优选,所述充氮气保护进行烧结的过程为:从室温升到1400℃,升温速度50℃/分钟, 在1400℃保温2~2.5小时;然后从1400℃升到1550~1600℃:升温速度25℃/分钟,在1550~1600℃保温2.5-3小时。
本发明复合陶瓷材料由Al2O3等特殊的材料制成,具有强度高、耐热性和硬度、抗氧化和抗侵蚀性能等优良性质。本发明添加了亚纳米级Y2O3,粒度20-200nm,在烧制过程中,亚纳米级Y2O3进入Al2O3晶格中,有Al2O3在低温下被充分烧结,使得制品显气孔率下降明显,从而提高了常温、高温强度,同时对热震性能有所改善。
与现有技术相比,本发明采用特殊的陶瓷材质替代金属5-Cr25Ni20Si2和Co22作为耐热滑块在加热炉上应用,表现出了耐磨损、耐高温、抗氧化、能抵抗机械载负荷和滑动摩擦和抗热震性能好等优良性能,并且还能够消除“黑印”,提高轧钢成品率,降低了滑块使用成本。
具体实施方式
下面结合具体实施方式,对发明的技术方案作进一步具体的说明。
实施例一:该耐磨耐高温的复合陶瓷材料的制备方法包括以下步骤:
A.将Al2O3 95 份、TiC6份、WO3 1 份、Y2O3稀土复合添加剂 4份、BeO 0.1 份、ZrB20.1份、TiN0.2份、ZrB20.1份、TiN0.1份、液态湿混剂(可以采用无水乙醇、无水甲醇)95.5份依次装入球磨机,球磨72h,直至粉料直径为2~4um后,将料浆进行真空干燥去除无水乙醇,得到粉料,将粉料破碎、过筛,保存备用;
B.将制好的粉料装入滑块上层的模具中,采用等静压加压成型,其压力为150MPa,对成型后的陶瓷件进行粗加工,加工后的半成品放入高温炉中进行烧结,从室温升到1400℃,升温速度50℃/分钟, 在1400℃保温2~2.5小时;然后从1400℃升到1580℃:升温速度25℃/分钟,在 1580℃保温2.5-3小时,使用中性的氮气气氛进行保护,然后随炉冷却;
C.将烧结好的复合陶瓷组件进行后期处理,即得耐磨耐高温的复合陶瓷材料。在Al2O3复合陶瓷添加了TiC、WO3、Y2O3、BeO、ZrB、TiN,尤其是Y2O3、ZrB、TiN组合,使Al2O3复合陶瓷材料的性能大幅度提高,使材料具有更好的抗热震稳定性、韧性,特别是耐压强度和高温抗折强度大幅度提升。
实施例二:该步进式加热炉的滑块的制备方法包括以下步骤:
A.将Al2O3 97 份、TiC8份、WO3 1.5 份、Y2O3稀土复合添加剂 7份、BeO 0.15 份、ZrB20.1份、TiN0.2份、ZrB20.2份、TiN0.1份、液态湿混剂(可以采用无水乙醇、无水甲醇)135份依次装入球磨机,球磨72h,直至粉料直径为2~4um后,将料浆进行真空干燥去除无水乙醇,得到粉料,将粉料破碎、过筛,保存备用;
B.将制好的粉料装入滑块上层的模具中,采用等静压加压成型,其压力为180MPa,对成型后的陶瓷件进行粗加工,加工后的半成品放入高温炉中进行烧结,从室温升到1400℃,升温速度50℃/分钟, 在1400℃保温2~2.5小时;然后从1400℃升到1600℃:升温速度25℃/分钟,在 1600℃保温2.5-3小时,使用中性的氮气气氛进行保护,然后随炉冷却;
C.将烧结好的复合陶瓷组件进行后期处理,即得耐磨耐高温的复合陶瓷材料。在Al2O3复合陶瓷添加了TiC、WO3、Y2O3、BeO、ZrB、TiN,尤其是Y2O3、ZrB、TiN组合,使Al2O3复合陶瓷材料的性能大幅度提高,使材料具有更好的抗热震稳定性、韧性,特别是耐压强度和高温抗折强度大幅度提升。
实施例三:该用于步进式加热炉的滑块的制备方法包括以下步骤:
A. 将Al2O3 86 份、TiC3份、WO3 4 份、Y2O3稀土复合添加剂 2份、BeO 0.2份、液态湿混剂(可以采用无水乙醇、无水甲醇)96份依次装入球磨机,球磨72h,直至粉料直径为2~4um后,将料浆进行真空干燥去除无水乙醇,得到粉料,将粉料破碎、过筛,保存备用;
B.将制好的粉料装入滑块上层的模具中,采用等静压加压成型,其压力为160MPa,对成型后的陶瓷件进行粗加工,加工后的半成品放入高温炉中进行烧结,从室温升到1400℃,升温速度50℃/分钟, 在1400℃保温2~2.5小时;然后从1400℃升到1600℃:升温速度25℃/分钟,在 1550℃保温2.5-3小时,使用中性的氮气气氛进行保护,然后随炉冷却;
C.将烧结好的复合陶瓷组件进行后期处理,然后制品进行三维定位测量,并对制品进行精加工,精加工的复合陶瓷组件经过耐热合金螺栓和金属底座装配后即得成品。在Al2O3复合陶瓷添加了TiC、WO3、Y2O3、BeO、ZrB、TiN,使Al2O3复合陶瓷材料的性能得到一定幅度提高,使材料具有较好的抗热震稳定性、韧性,耐压强度和高温抗折强度得以提升。
实施例四:该用于步进式加热炉的滑块的制备方法包括以下步骤:
A. 将Al2O3 90 份、TiC1.5份、WO3 5 份、Y2O3稀土复合添加剂8份、BeO 0.2份、液态湿混剂(可以采用无水乙醇、无水甲醇)113份依次装入球磨机,球磨72h,直至粉料直径为2~4um后,将料浆进行真空干燥去除无水乙醇,得到粉料,将粉料破碎、过筛,保存备用;
B.将制好的粉料装入滑块上层的模具中,采用等静压加压成型,其压力为170MPa,对成型后的陶瓷件进行粗加工,加工后的半成品放入高温炉中进行烧结,从室温升到1400℃,升温速度50℃/分钟, 在1400℃保温2~2.5小时;然后从1400℃升到1600℃:升温速度25℃/分钟,在 1590℃保温2.5-3小时,使用中性的氮气气氛进行保护,然后随炉冷却;
C.将烧结好的复合陶瓷组件进行后期处理,然后制品进行三维定位测量,并对制品进行精加工,精加工的复合陶瓷组件经过耐热合金螺栓和金属底座装配后即得成品。在Al2O3复合陶瓷添加了TiC、WO3、Y2O3、BeO、ZrB、TiN,使Al2O3复合陶瓷材料的性能得到一定幅度提高,使材料具有较好的抗热震稳定性、韧性,耐压强度和高温抗折强度得以提升。
用实施例一和实施例二分别制成的2块滑块使用1年后,检验结果如下:
1、陶瓷耐热滑块上表面没有观察到磨损情况,陶瓷耐热滑块没有发现裂纹和剥落的情况;
2、陶瓷耐热滑块在炉内经受住了频繁的温度波动(900℃-1300℃);
3、坯在炉内连续步进,陶瓷耐热滑块经受住了连续高频次的机械负荷压力,钢坯重达2~3吨;
4、由于陶瓷材料的导热系数远远低于合金材料的导热系数,加热炉内钢坯与Al2O3复合陶瓷耐热滑块接触的部分不会产生“黑印”。
用实施例三和实施例四分别制成的2块滑块使用半年后,检验结果如下:
1、陶瓷耐热滑块上表面没有观察到磨损情况,陶瓷耐热滑块没有发现裂纹和剥落的情况;
2、陶瓷耐热滑块在炉内经受住了频繁的温度波动(900℃-1300℃);
3、坯在炉内连续步进,陶瓷耐热滑块经受住了连续高频次的机械负荷压力,钢坯重达2~3吨;
4、由于陶瓷材料的导热系数远远低于合金材料的导热系数,加热炉内钢坯与Al2O3复合陶瓷耐热滑块接触的部分不会产生“黑印”。
本发明的实施例一、二与购得常规陶瓷加热炉滑块作对比,其结果如下:
本发明的实施例三、四与购得常规陶瓷加热炉滑块作对比,其结果如下:
Claims (5)
1.一种耐磨耐高温的复合陶瓷材料,其特征在于所述复合陶瓷材料主要由以下组分按重量比配制而成:Al2O3 85~99份、TiC 1~10份、WO3 1~5份、Y2O3添加剂1~8份、BeO 0.1~0.2份。
2.根据权利要求1所述的一种耐磨耐高温的复合陶瓷材料,其特征在于所述复合陶瓷主要由以下陶瓷粉料按重量比烧结而成:Al2O3 93~97份、TiC6~10份、WO3 1~2份、亚纳米级Y2O3添加剂 4~7份、BeO 0.1~0.2份、ZrB20.1~0.2份、TiN0.1~0.2份。
3.根据权利要求1所述的一种耐磨耐高温的复合陶瓷材料,其特征在于所述复合陶瓷材料的生产工艺为:A.精确称量各组分,将各组分依次装入球磨机,加入陶瓷粉料总重量0.9~1.2倍重量的液态湿混剂,球磨直至粉料直径为2~4um后,将料浆进行真空干燥去除液态湿混剂,得到粉料,将粉料破碎、过筛,保存备用;
B.将制好的粉料装入滑块上层的模具中,采用等静压加压成型,其压力为150~180MPa,对成型后的陶瓷件进行粗加工,加工后的半成品放入高温炉中进行烧结,使用中性的充氮气保护进行烧结,从室温逐渐升温1580℃保温烧成,然后随炉冷却,即得成品。
4.根据权利要求3所述的一种耐磨耐高温的复合陶瓷材料,其特征在于所述液态湿混剂为无水乙醇、无水甲醇中的一种。
5.根据权利要求3所述的一种耐磨耐高温的复合陶瓷材料,其特征在于所述的充氮气保护进行烧结的过程为:从室温升到1400℃,升温速度50℃/分钟, 在1400℃保温2~2.5小时;然后从1400℃升到1550~1600℃:升温速度25℃/分钟,在1550~1600℃保温2.5-3小时。
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