CN106518118A - 一种复合挤压模具材料的制备方法 - Google Patents
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Abstract
本发明涉及一种复合挤压模具材料的制备方法,属于模具材料制备技术领域。本发明首先将废旧粘胶纤维预处理后,经氧化和碳化,得到粘胶基碳纤维,再将二乙三胺五乙酸溶于去离子水后,加入硝酸铝,得到氧化铝纤维前驱体,接着将其与十二烷基硫酸钠等物质混合,经纺丝和煅烧,得到微米级氧化铝纤维,最后将其与粘胶基碳纤维、氮化铬等物质进行混合挤压,得到坯料,将其高温煅烧后,即可得到复合挤压模具材料。本发明制备的复合挤压模具材料强度高,抗弯强度达到1452MPa以上,在操作过程中不易产生裂纹,不会影响挤压型材表面的质量;使用寿命长,使用寿命达到1450次/模以上。
Description
技术领域
本发明涉及一种复合挤压模具材料的制备方法,属于模具材料制备技术领域。
背景技术
挤压模具作为有色金属热挤压生产中的关键构件,它的使用寿命和质量将极大的影响挤压型材的质量、效率和成本。在整个热挤压过程中,热挤压模具处于极其苛刻的工作环境中,这就要求挤压模具材料具有较高的高温硬度、高温强度和抗磨损性能。同时随着生产规模的迅速扩大,还需要考虑热挤压模具的成本以及可修复性。
目前采用传统的热作钢,如H11、H12或H13制造的挤压模具材料,由于其使用寿命短、高温强度和耐磨性差,导致热挤压型材表面质量差、尺寸精度低,同时还需经常更换模具,生产效率低,增加生产成本。而作为另一较为先进的陶瓷模具而言,虽然其使用寿命大大提高,但由于价格昂贵,易开裂且无法进行修复,对于大规模生产存在一定困难。
发明内容
本发明所要解决的技术问题:针对传统的挤压模具材料使用寿命短,强度低,导致挤压型材表面质量差的问题,本发明首先将废旧粘胶纤维预处理后,经氧化和碳化,得到粘胶基碳纤维,再将二乙三胺五乙酸溶于去离子水后,加入硝酸铝,得到氧化铝纤维前驱体,接着将其与十二烷基硫酸钠等物质混合,经纺丝和煅烧,得到微米级氧化铝纤维,最后将其与粘胶基碳纤维、氮化铬等物质进行混合挤压,得到坯料,将其高温煅烧后,即可得到复合挤压模具材料。本发明制备的复合挤压模具材料使用寿命长,强度高,不会影响挤压型材表面的质量。
为解决上述技术问题,本发明采用的技术方案是:
(1)称取10~20g废旧粘胶纤维加入到烧杯中,并加入200~300mL甲苯和5~8g甲基硅油,搅拌20~30min,过滤,收集滤渣,将滤渣加入到盛有200~300mL质量分数为20%氯化铵溶液的烧杯中,浸泡2~3h,随后过滤,得到二次滤渣,并用去离子水洗涤二次滤渣3~5次,得到预处理后的胶粘纤维;
(2)将上述预处理后的胶粘纤维加入到氧化炉中,在200~220℃下氧化1~2h,随后转移至碳化炉中,在1300~1500℃碳化3~4h,随后自然冷却至室温,得到粘胶基碳纤维,备用;
(3)取3~5g二乙三胺五乙酸加入到烧杯中,再向烧杯中加入100~200mL去离子水,并对其进行加热至80~90℃,保温搅拌30~40min,待二乙三胺五乙酸全部溶解后,再加入8~12g硝酸铝,搅拌反应2~3h,待反应结束后,静置陈化1~2h,随后过滤,收集滤渣,将滤渣置于干燥箱中,在80~90℃下干燥3~4h,得到氧化铝纤维前驱体; (4)将上述氧化铝纤维前驱体加入到烧杯中,再依次加入1~3g十二烷基硫酸钠、4~6g聚酰胺蜡和100~200mL去离子水,搅拌10~20min,得到纺丝液,随后置于纺丝机中进行纺丝,控制纺丝温度为160~180℃,得到原丝,将原丝置于马弗炉中,在700~800℃下煅烧2~3h,再随炉冷却至室温,得到微米级氧化铝纤维;
(5)按重量份数计,称取10~15份步骤(2)备用的粘胶基碳纤维、30~40份上述微米级氧化铝纤维、6~8份纳米碳化钛、3~5份氮化铬、8~12份氧化锆和1~3份氧化钇,加入到球磨机中球磨2~3h,得到混合粉末,将混合粉末加入到等静压成型机中,在160~170MPa下压制成型,得到坯料,将坯料加入到石墨模具中,以10~15℃/min升温至1000~1200℃,保温1~2h,随后以8~12℃/min升温至1300~1400℃,保温30~40min,再随炉冷却至室温,得到复合挤压模具材料。
本发明制备的复合挤压模具材料抗弯强度达到1452MPa以上,断裂韧性为17MPa·m1/2以上,维氏硬度达到15.75GPa以上,1000℃时的膨胀系数低于4.521×10-6K-1,使用寿命达到1450次/模以上。
本发明与其他方法相比,有益技术效果是:
(1)本发明制备的复合挤压模具材料强度高,抗弯强度达到1452MPa以上,在操作过程中不易产生裂纹,不会影响挤压型材表面的质量;
(2)本发明制备的复合挤压模具材料使用寿命长,使用寿命达到1450次/模以上;
(3)本发明制备的复合挤压模具材料制备步骤简单,所需成本低。
具体实施方式
首先称取10~20g废旧粘胶纤维加入到烧杯中,并加入200~300mL甲苯和5~8g甲基硅油,搅拌20~30min,过滤,收集滤渣,将滤渣加入到盛有200~300mL质量分数为20%氯化铵溶液的烧杯中,浸泡2~3h,随后过滤,得到二次滤渣,并用去离子水洗涤二次滤渣3~5次,得到预处理后的胶粘纤维;将上述预处理后的胶粘纤维加入到氧化炉中,在200~220℃下氧化1~2h,随后转移至碳化炉中,在1300~1500℃碳化3~4h,随后自然冷却至室温,得到粘胶基碳纤维,备用;取3~5g二乙三胺五乙酸加入到烧杯中,再向烧杯中加入100~200mL去离子水,并对其进行加热至80~90℃,保温搅拌30~40min,待二乙三胺五乙酸全部溶解后,再加入8~12g硝酸铝,搅拌反应2~3h,待反应结束后,静置陈化1~2h,随后过滤,收集滤渣,将滤渣置于干燥箱中,在80~90℃下干燥3~4h,得到氧化铝纤维前驱体;将上述氧化铝纤维前驱体加入到烧杯中,再依次加入1~3g十二烷基硫酸钠、4~6g聚酰胺蜡和100~200mL去离子水,搅拌10~20min,得到纺丝液,随后置于纺丝机中进行纺丝,控制纺丝温度为160~180℃,得到原丝,将原丝置于马弗炉中,在700~800℃下煅烧2~3h,再随炉冷却至室温,得到微米级氧化铝纤维;最后按重量份数计,称取10~15份备用的粘胶基碳纤维、30~40份上述微米级氧化铝纤维、6~8份纳米碳化钛、3~5份氮化铬、8~12份氧化锆和1~3份氧化钇,加入到球磨机中球磨2~3h,得到混合粉末,将混合粉末加入到等静压成型机中,在160~170MPa下压制成型,得到坯料,将坯料加入到石墨模具中,以10~15℃/min升温至1000~1200℃,保温1~2h,随后以8~12℃/min升温至1300~1400℃,保温30~40min,再随炉冷却至室温,得到复合挤压模具材料。
实例1
首先称取20g废旧粘胶纤维加入到烧杯中,并加入300mL甲苯和8g甲基硅油,搅拌30min,过滤,收集滤渣,将滤渣加入到盛有300mL质量分数为20%氯化铵溶液的烧杯中,浸泡3h,随后过滤,得到二次滤渣,并用去离子水洗涤二次滤渣5次,得到预处理后的胶粘纤维;将上述预处理后的胶粘纤维加入到氧化炉中,在220℃下氧化2h,随后转移至碳化炉中,在1500℃下碳化4h,随后自然冷却至室温,得到粘胶基碳纤维,备用;取5g二乙三胺五乙酸加入到烧杯中,再向烧杯中加入200mL去离子水,并对其进行加热至90℃,保温搅拌40min,待二乙三胺五乙酸全部溶解后,再加入12g硝酸铝,搅拌反应3h,待反应结束后,静置陈化2h,随后过滤,收集滤渣,将滤渣置于干燥箱中,在90℃下干燥4h,得到氧化铝纤维前驱体;将上述氧化铝纤维前驱体加入到烧杯中,再依次加入3g十二烷基硫酸钠、6g聚酰胺蜡和200mL去离子水,搅拌20min,得到纺丝液,随后置于纺丝机中进行纺丝,控制纺丝温度为180℃,得到原丝,将原丝置于马弗炉中,在800℃下煅烧3h,再随炉冷却至室温,得到微米级氧化铝纤维;按重量份数计,称取15份备用的粘胶基碳纤维、40份上述微米级氧化铝纤维、8份纳米碳化钛、5份氮化铬、12份氧化锆和3份氧化钇,加入到球磨机中球磨3h,得到混合粉末,将混合粉末加入到等静压成型机中,在170MPa下压制成型,得到坯料,将坯料加入到石墨模具中,以15℃/min升温至1200℃,保温2h,随后以12℃/min升温至1400℃,保温40min,再随炉冷却至室温,得到复合挤压模具材料。
经检测,本发明制备的复合挤压模具材料抗弯强度达到1462MPa,断裂韧性为18MPa·m1/2,维氏硬度达到15.85GPa,1000℃时的膨胀系数为4.421×10-6K-1,使用寿命达到1455次/模。
实例2
首先称取10g废旧粘胶纤维加入到烧杯中,并加入200mL甲苯和5g甲基硅油,搅拌20min,过滤,收集滤渣,将滤渣加入到盛有200mL质量分数为20%氯化铵溶液的烧杯中,浸泡2h,随后过滤,得到二次滤渣,并用去离子水洗涤二次滤渣3次,得到预处理后的胶粘纤维;将上述预处理后的胶粘纤维加入到氧化炉中,在200℃下氧化1h,随后转移至碳化炉中,在1300℃下碳化3h,随后自然冷却至室温,得到粘胶基碳纤维,备用;取3g二乙三胺五乙酸加入到烧杯中,再向烧杯中加入100mL去离子水,并对其进行加热至80℃,保温搅拌30min,待二乙三胺五乙酸全部溶解后,再加入8g硝酸铝,搅拌反应2h,待反应结束后,静置陈化1h,随后过滤,收集滤渣,将滤渣置于干燥箱中,在80℃下干燥3h,得到氧化铝纤维前驱体;将上述氧化铝纤维前驱体加入到烧杯中,再依次加入1g十二烷基硫酸钠、4g聚酰胺蜡和100mL去离子水,搅拌10min,得到纺丝液,随后置于纺丝机中进行纺丝,控制纺丝温度为160℃,得到原丝,将原丝置于马弗炉中,在700℃下煅烧2h,再随炉冷却至室温,得到微米级氧化铝纤维;按重量份数计,称取10份备用的粘胶基碳纤维、30份上述微米级氧化铝纤维、6份纳米碳化钛、3份氮化铬、8份氧化锆和1份氧化钇,加入到球磨机中球磨2h,得到混合粉末,将混合粉末加入到等静压成型机中,在160MPa下压制成型,得到坯料,将坯料加入到石墨模具中,以10℃/min升温至1000℃,保温1h,随后以8℃/min升温至1300℃,保温30min,再随炉冷却至室温,得到复合挤压模具材料。
本发明制备的复合挤压模具材料抗弯强度达到1458MPa,断裂韧性为18MPa·m1/2,维氏硬度达到15.95GPa,1000℃时的膨胀系数为4.511×10-6K-1,使用寿命达到1454次/模。
实例3
首先称取15g废旧粘胶纤维加入到烧杯中,并加入250mL甲苯和7g甲基硅油,搅拌25min,过滤,收集滤渣,将滤渣加入到盛有250mL质量分数为20%氯化铵溶液的烧杯中,浸泡3h,随后过滤,得到二次滤渣,并用去离子水洗涤二次滤渣4次,得到预处理后的胶粘纤维;将上述预处理后的胶粘纤维加入到氧化炉中,在210℃下氧化2h,随后转移至碳化炉中,在1400℃碳化3h,随后自然冷却至室温,得到粘胶基碳纤维,备用;取4g二乙三胺五乙酸加入到烧杯中,再向烧杯中加入150mL去离子水,并对其进行加热至85℃,保温搅拌35min,待二乙三胺五乙酸全部溶解后,再加入10g硝酸铝,搅拌反应3h,待反应结束后,静置陈化2h,随后过滤,收集滤渣,将滤渣置于干燥箱中,在85℃下干燥3h,得到氧化铝纤维前驱体;将上述氧化铝纤维前驱体加入到烧杯中,再依次加入2g十二烷基硫酸钠、5g聚酰胺蜡和150mL去离子水,搅拌15min,得到纺丝液,随后置于纺丝机中进行纺丝,控制纺丝温度为170℃,得到原丝,将原丝置于马弗炉中,在750℃下煅烧2h,再随炉冷却至室温,得到微米级氧化铝纤维;按重量份数计,称取12份备用的粘胶基碳纤维、35份上述微米级氧化铝纤维、7份纳米碳化钛、4份氮化铬、10份氧化锆和2份氧化钇,加入到球磨机中球磨3h,得到混合粉末,将混合粉末加入到等静压成型机中,在165MPa下压制成型,得到坯料,将坯料加入到石墨模具中,以12℃/min升温至1100℃,保温2h,随后以10℃/min升温至1350℃,保温35min,再随炉冷却至室温,得到复合挤压模具材料。
本发明制备的复合挤压模具材料抗弯强度达到1454MPa,断裂韧性为19MPa·m1/2,维氏硬度达到18.65GPa,1000℃时的膨胀系数为4.401×10-6K-1,使用寿命达到1451次/模。
Claims (1)
1.一种复合挤压模具材料的制备方法,其特征在于具体制备步骤为:
(1)称取10~20g废旧粘胶纤维加入到烧杯中,并加入200~300mL甲苯和5~8g甲基硅油,搅拌20~30min,过滤,收集滤渣,将滤渣加入到盛有200~300mL质量分数为20%氯化铵溶液的烧杯中,浸泡2~3h,随后过滤,得到二次滤渣,并用去离子水洗涤二次滤渣3~5次,得到预处理后的胶粘纤维;
(2)将上述预处理后的胶粘纤维加入到氧化炉中,在200~220℃下氧化1~2h,随后转移至碳化炉中,在1300~1500℃下碳化3~4h,自然冷却至室温,得到粘胶基碳纤维,备用;(3)取3~5g二乙三胺五乙酸加入到烧杯中,再向烧杯中加入100~200mL去离子水,并对其进行加热至80~90℃,保温搅拌30~40min,待二乙三胺五乙酸全部溶解后,再加入8~12g硝酸铝,搅拌反应2~3h,待反应结束后,静置陈化1~2h,随后过滤,收集滤渣,将滤渣置于干燥箱中,在80~90℃下干燥3~4h,得到氧化铝纤维前驱体;
(4)将上述氧化铝纤维前驱体加入到烧杯中,再依次加入1~3g十二烷基硫酸钠、4~6g聚酰胺蜡和100~200mL去离子水,搅拌10~20min,得到纺丝液,随后置于纺丝机中进行纺丝,控制纺丝温度为160~180℃,得到原丝,将原丝置于马弗炉中,在700~800℃下煅烧2~3h,再随炉冷却至室温,得到微米级氧化铝纤维;
(5)按重量份数计,称取10~15份步骤(2)备用的粘胶基碳纤维、30~40份上述微米级氧化铝纤维、6~8份纳米碳化钛、3~5份氮化铬、8~12份氧化锆和1~3份氧化钇,加入到球磨机中球磨2~3h,得到混合粉末,将混合粉末加入到等静压成型机中,在160~170MPa下压制成型,得到坯料,将坯料加入到石墨模具中,以10~15℃/min升温至1000~1200℃,保温1~2h,随后以8~12℃/min升温至1300~1400℃,保温30~40min,再随炉冷却至室温,得到复合挤压模具材料。
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