CN106495724A - 一种用于水泥磨陶瓷球的二次成型方法 - Google Patents
一种用于水泥磨陶瓷球的二次成型方法 Download PDFInfo
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Abstract
本发明公开了一种用于水泥磨陶瓷球的二次成型方法,包括将各种原料混合后压制成球状坯体的步骤,将球状坯体烧结的步骤,在烧结后,将烧结产品放入球磨机,加入水和氮化硼进行研磨,然后出磨干燥后制得陶瓷球。本发明不仅提高了陶瓷球的光滑性、耐磨性、抗冲击性等性能,还筛选出表面具有缺陷、硬度小、抗压能力小的陶瓷球,提高了其生产效率,此外,生产的水泥细度均匀、性能稳定、散差较小,使其后期不会发生不规则变形,保障了水泥的质量。
Description
技术领域
本发明涉及无机非金属材料(陶瓷)领域,具体的说是一种用于水泥磨陶瓷球的二次成型方法。
背景技术
随着工业技术和经济的发展,陶瓷球具有高耐磨性、硬度大、抗冲击性强等优异性能使其在广泛的领域备受关注。陶瓷球以其高硬度、高弹性模量、低密度、低摩擦因数、耐磨、化学性能和热学性能稳定等性能,被认为是高速、高精度的理想滚动体。球体表面凹凸及裂纹等表面缺陷对陶瓷球的运动精度和寿命有着很大的影响。因此,要达到高的表面质量要求,延长陶瓷球的使用寿命,提高陶瓷球的生产率,在陶瓷球制备阶段,提高陶瓷球性能、消除表面损伤是关键。一般在制备烧结过程结束后陶瓷球的制备工作就将完成,这样烧结后陶瓷球性能层次不齐,降低了陶瓷球的使用寿命、生产效率。目前有人采用烧结后在球磨机内加水和陶瓷球再次研磨处理,在陶瓷球滚压及陶瓷球和球磨机的机械作用下容易在陶瓷球表面造成如划痕和微裂纹等表面损伤,陶瓷球的光滑性及其性能会有所降低,同时也不能保证球形的尺寸。
发明内容
发明的目的是为了解决上述技术问题的不足,提供一种用于水泥磨陶瓷球的二次成型方法,提高了陶瓷球的光滑性、耐磨性、抗冲击性等性能,筛选出性能不好、表面缺陷较大的陶瓷球,延长其使用寿命,提高了生产效率。
本发明为解决上述技术问题的不足而采用的技术方案是:一种用于水泥磨陶瓷球的二次成型方法包括将各种原料混合后压制成球状坯体的步骤,将球状坯体烧结的步骤,在烧结后,将烧结产品放入球磨机,加入水和氮化硼进行研磨,研磨5-24h后出磨,干燥后制得陶瓷球,其中烧结产品、水和氮化硼按重量份数加入的比例为:烧结产品80-120份、水5-15份、氮化硼1-2份。
本发明,所述的研磨时烧结产品、水和氮化硼按重量份数加入的比例为:烧结产品100份、水10份、氮化硼1份。
本发明,所述的氮化硼的粒度为20-200nm。
本发明,所述的将球状坯体烧结的步骤中,烧结升温过程分为三段:
a: 将球状坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b: 将球状坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c: 将球状坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h。
本发明,所述的烧结产品中含有氮化硼。
本发明的有益效果是:
其一、在烧结后,将烧结产品再次放入球磨机,加入水和氮化硼进行研磨,此处,所加入的氮化硼实现两种作用:首先,由于氮化硼本身的硬度较高,对一些表面具有缺陷或者表层内部有缺陷的烧结陶瓷球有一定的破坏作用,对于该类表面缺陷较大、硬度小、抗压能力小的陶瓷球在二次成型过程中由于摩损较大而被筛选出来,这对后续陶瓷球用于水泥研磨提高生产效率、保证产品质量有很大的影响,如果此时不筛选出来,后续在制备水泥过程中,表面具有缺陷、硬度小、抗压能力小的陶瓷球在很短的时间内就被破坏掉,不仅加速了其他正常陶瓷球的毁坏速度,从而降低陶瓷球的使用寿命,而且断裂或破碎的陶瓷球还会影响水泥的质量,对水泥有一定的污染,影响生产效率,浪费财力和人力;其次,采用较硬的氮化硼,同时限定其粒度为20-200nm,实现了研磨过程中在瞬时高温高压的作用下,在粗糙表面的触点上发生固体间的接触,而产生固体摩擦,氮化硼具有极好的润滑性能以及高温稳定性,即便是在极高的温度下氮化硼依然能保持其润滑性和惰性,在研磨过程中氮化硼可以减少陶瓷球表面接触压力,防止晶界微裂纹的形成和扩展粘连,减少微裂纹相互连结在一起形成大裂纹以导致晶粒的拨出或断裂从而减少陶瓷球的寿命,提高陶瓷球产品的表面洁度使其获得良好的表面质量。
其二、在制得烧结产品时,合理调整烧结过程中的升温曲线实现烧结产品在一次成型中得到较好的性能,采取分段升温,并且在不同的温度段匹配不同的升温速率,同时在每一段升温后均精确控制一定的保温时间;例如在烧结过程中,将球状坯体预热到500℃,升温速率为11-20℃/min,将球状坯体从500℃升温到1000℃,升温速率为6-10℃/min,将球状坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,申请人通过多次实验发现:采用上述三段式升温方式最为合理;其次在每一次升温后均施加一定的保温时间,上述步骤使得陶瓷体获得了较好的致密化效果,从而提高了陶瓷体硬度、耐磨性、抗冲击性等性能。
具体实施方式
本发明为一种用于水泥磨陶瓷球的二次成型方法,其具体的实施方式为:将各种原料混合后压制成球状坯体的步骤,将球状坯体烧结的步骤,在烧结后,将烧结产品放入球磨机,加入水和氮化硼进行研磨,研磨5-24h后出磨,干燥后制得陶瓷球,其中烧结产品、水和氮化硼按重量份数加入的比例为:烧结产品80-120份、水5-15份、氮化硼1-2份。
本发明,研磨时烧结产品、水和氮化硼按重量份数加入的比例为:烧结产品100份、水10份、氮化硼1份。
本发明,所述的氮化硼的粒度为20-200nm。
本发明,所述的将球状坯体烧结的步骤中,烧结升温过程分为三段:
a: 将球状坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b: 将球状坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c: 将球状坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h。
本发明,所述的烧结产品中含有氮化硼。
实施例1
首先将氧化铝微粉97-99份、氧化铝晶须0.1-0.5份、氧化锆0.4-2.5份、结合剂0.05-0.1份放入球磨机,加入水进行湿磨,运行30-45时,过0.063mm筛出磨放入泥浆池中搅拌陈腐36-50h,再进行除铁得到含水量60%的料浆,料浆细度D50≤1.2μm;其中,所述的氧化铝微粉粒径为0.1-2μm;所述的氧化锆为纳米颗粒,粒径为4-60nm;所述的氧化铝晶须平均直径为0.5-2μm,平均长度为8-100μm。所述的结合剂为La2O3、Y2O3、SiO2、TiO2、CaO、MgO、滑石中的任意一种或多种混合物。然后,将得到的料浆输入喷雾干燥塔中进行喷雾制粉,将干燥后的粉料输送到大料仓中陈腐2-4天得到含水量1.5-3%的粉料,采用挤压成型或注射成型的方法成坯,得到含水量0.5-1%的球形坯体;将球形坯体预先在室温放置,使球形坯体温度降至10-150℃,然后送入高温隧道窑中烧结,经在1300-1380℃保温5.5-8h即为烧结产品;其中烧结升温过程分为三段:
a:将球形坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b:将球形坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c:将球形坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h,即为陶瓷球的一次成型。
最后按重量份数及加入的比例将烧结产品100份、水10份、氮化硼1份(粒度为20-200nm)放入球磨机进行研磨,研磨5-24h,即为陶瓷球的二次成型。陶瓷球出磨干燥后包装,就得到了一种用于水泥磨的氧化锆-刚玉复合陶瓷体,具有光滑的表面,形状为球形,强度大、耐磨性和抗冲击性强,体积密度>3.7g/cm3,莫氏硬度为9,吸水量<0.01%,当量磨耗<0.05%。
实施例2
首先将氧化铝微粉97-99份、氧化铝晶须0.1-0.5份、氧化锆0.4-2.5份、结合剂0.05-0.1份放入球磨机,加入水进行湿磨,运行30-45时,过0.063mm筛出磨放入泥浆池中搅拌陈腐36-50h,再进行除铁得到含水量60%的料浆,料浆细度D50≤1.2μm;其中,所述的氧化铝微粉粒径为0.1-2μm;所述的氧化锆为纳米颗粒,粒径为4-60nm;氧化铝晶须平均直径为0.5-2μm,平均长度为8-100μm;结合剂为La2O3、Y2O3、SiO2、TiO2、CaO、MgO、滑石中的任意一种或多种混合物;氮化硼的粒度为20-200nm。然后将得到的料浆输入喷雾干燥塔中进行喷雾制粉,将干燥后的粉料输送到大料仓中陈腐2-4天得到含水量1.5-3%的粉料,采用挤压成型或注射成型的方法成坯,得到含水量0.5-1%的球形坯体;将球形坯体预先在室温放置,使球形坯体温度降至10-150℃,然后送入高温隧道窑中烧结,经在1300-1380℃保温5.5-8h即为烧结产品;其中烧结升温过程分为三段:
a:将球形坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b:将球形坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c:将球形坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h,即为陶瓷球的一次成型。
最后按重量份数将烧结产品80份、水5份、粒度为20nm的氮化硼1.5份放入球磨机进行研磨,研磨5h即为陶瓷球的二次成型,陶瓷球出磨干燥后包装即可。
实施例3
首先将氧化铝微粉97-99份、氧化铝晶须0.1-0.5份、氧化锆0.4-2.5份、结合剂0.05-0.1份放入球磨机,加入水进行湿磨,运行30-45时,过0.063mm筛出磨放入泥浆池中搅拌陈腐36-50h,再进行除铁得到含水量60%的料浆,料浆细度D50≤1.2μm;其中,所述的氧化铝微粉粒径为0.1-2μm;所述的氧化锆为纳米颗粒,粒径为4-60nm;氧化铝晶须平均直径为0.5-2μm,平均长度为8-100μm;结合剂为La2O3、Y2O3、SiO2、TiO2、CaO、MgO、滑石中的任意一种或多种混合物;氮化硼的粒度为20-200nm。然后将得到的料浆输入喷雾干燥塔中进行喷雾制粉,将干燥后的粉料输送到大料仓中陈腐2-4天得到含水量1.5-3%的粉料,采用挤压成型或注射成型的方法成坯,得到含水量0.5-1%的球形坯体;将球形坯体预先在室温放置,使球形坯体温度降至10-150℃,然后送入高温隧道窑中烧结,经在1300-1380℃保温5.5-8h即为烧结产品;其中烧结升温过程分为三段:
a:将球形坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b:将球形坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c:将球形坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h,即为陶瓷球的一次成型。
最后按重量份数将烧结产品95份、水15份、粒度为100nm的氮化硼2份放入球磨机进行研磨,研磨10h即为陶瓷球的二次成型,陶瓷球出磨干燥后包装即可。
实施例4
首先将氧化铝微粉97-99份、氧化铝晶须0.1-0.5份、氧化锆0.4-2.5份、结合剂0.05-0.1份放入球磨机,加入水进行湿磨,运行30-45时,过0.063mm筛出磨放入泥浆池中搅拌陈腐36-50h,再进行除铁得到含水量60%的料浆,料浆细度D50≤1.2μm;其中,所述的氧化铝微粉粒径为0.1-2μm;所述的氧化锆为纳米颗粒,粒径为4-60nm;氧化铝晶须平均直径为0.5-2μm,平均长度为8-100μm;结合剂为La2O3、Y2O3、SiO2、TiO2、CaO、MgO、滑石中的任意一种或多种混合物;氮化硼的粒度为20-200nm。然后将得到的料浆输入喷雾干燥塔中进行喷雾制粉,将干燥后的粉料输送到大料仓中陈腐2-4天得到含水量1.5-3%的粉料,采用挤压成型或注射成型的方法成坯,得到含水量0.5-1%的球形坯体;将球形坯体预先在室温放置,使球形坯体温度降至10-150℃,然后送入高温隧道窑中烧结,经在1300-1380℃保温5.5-8h即为烧结产品;其中烧结升温过程分为三段:
a:将球形坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b:将球形坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c:将球形坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h,即为陶瓷球的一次成型。
最后按重量份数将烧结产品120份、水9份、粒度为200nm的氮化硼1份放入球磨机进行研磨,研磨24h即为陶瓷球的二次成型,陶瓷球出磨干燥后包装即可。
实施例5
首先将氧化铝微粉97-99份、氧化铝晶须0.1-0.5份、氧化锆0.4-2.5份、结合剂0.05-0.1份、氮化硼1份放入球磨机,加入水进行湿磨,运行30-45时,过0.063mm筛出磨放入泥浆池中搅拌陈腐36-50h,再进行除铁得到含水量60%的料浆,料浆细度D50≤1.2μm;其中,所述的氧化铝微粉粒径为0.1-2μm;所述的氧化锆为纳米颗粒,粒径为4-60nm;氧化铝晶须平均直径为0.5-2μm,平均长度为8-100μm;结合剂为La2O3、Y2O3、SiO2、TiO2、CaO、MgO、滑石中的任意一种或多种混合物;氮化硼的粒度为20-200nm。然后将得到的料浆输入喷雾干燥塔中进行喷雾制粉,将干燥后的粉料输送到大料仓中陈腐2-4天得到含水量1.5-3%的粉料,采用挤压成型或注射成型的方法成坯,得到含水量0.5-1%的球形坯体;将球形坯体预先在室温放置,使球形坯体温度降至10-150℃,然后送入高温隧道窑中烧结,经在1300-1380℃保温5.5-8h即为烧结产品;其中烧结升温过程分为三段:
a:将球形坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b:将球形坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c:将球形坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h,即为陶瓷球的一次成型。
最后按重量份数将烧结产品100份、水10份、氮化硼1份(与原料中加入的氮化硼一样)放入球磨机进行研磨,研磨5-24h即为陶瓷球的二次成型,陶瓷球出磨干燥后包装即可。
本实施例在陶瓷球二次成型的过程中筛选出的硬度小、抗压能力低、表面缺陷较大的陶瓷球磨损体,可根据陶瓷球的原料配比将陶瓷球磨损体增加所需成分放入球磨机进行湿磨,使其再次循环利用制备陶瓷球,既节约了原料,工艺简单,降低了生产成本,又使陶瓷球磨损体得到利用,同时在陶瓷球生产过程中无副产品产生,且对环境无污染。
为了进一步说明本发明,在陶瓷球二次成型过程中研究加入不同的物质进行研磨的情况如下所示:
从上表可以看出在陶瓷球二次成型过程中加入氮化硼(BN)研磨后的陶瓷球表面粗糙度较低,表面比较光滑,当量耐磨较小,性能优异,从而提高了陶瓷球的生产效率,延长了其使用寿命。
Claims (5)
1.一种用于水泥磨陶瓷球的二次成型方法,包括将各种原料混合后压制成球状坯体的步骤,将球状坯体烧结的步骤,其特征在于:在烧结后,将烧结产品放入球磨机,加入水和氮化硼进行研磨,研磨5-24h后出磨,干燥后制得陶瓷球,其中烧结产品、水和氮化硼按重量份数加入的比例为:烧结产品80-120份、水5-15份、氮化硼1-2份。
2.如权利要求1所述的一种用于水泥磨陶瓷球的二次成型方法,其特征在于,研磨时烧结产品、水和氮化硼按重量份数加入的比例为:烧结产品100份、水10份、氮化硼1份。
3.如权利要求1所述的一种用于水泥磨陶瓷球的二次成型方法,其特征在于,所述的氮化硼的粒度为20-200nm。
4.如权利要求1所述的一种用于水泥磨陶瓷球的二次成型方法,其特征在于,所述的将球状坯体烧结的步骤中,烧结升温过程分为三段:
a: 将球状坯体预热到500℃,升温速率为11-20℃/min,保温时间为0.5-2h;
b: 将球状坯体从500℃升温到1000℃,升温速率为6-10℃/min,保温时间为1-3h;
c: 将球状坯体从1000℃升温到1300-1380℃,升温速率为1-5℃/min,保温时间为5.5-8h。
5.如权利要求1所述的一种用于水泥磨陶瓷球的二次成型方法,其特征在于,所述的烧结产品中含有氮化硼。
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CN1113931A (zh) * | 1994-06-11 | 1995-12-27 | 王魁久 | 陶瓷球的加工工艺及其设备 |
CN105859258A (zh) * | 2016-04-02 | 2016-08-17 | 山东天汇研磨耐磨技术开发有限公司 | 一种水泥球磨机用陶瓷研磨球及其制备方法 |
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CN1113931A (zh) * | 1994-06-11 | 1995-12-27 | 王魁久 | 陶瓷球的加工工艺及其设备 |
CN105859258A (zh) * | 2016-04-02 | 2016-08-17 | 山东天汇研磨耐磨技术开发有限公司 | 一种水泥球磨机用陶瓷研磨球及其制备方法 |
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