CN107226682A - 一种高温耐火陶瓷及其制备方法 - Google Patents

一种高温耐火陶瓷及其制备方法 Download PDF

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CN107226682A
CN107226682A CN201710615237.4A CN201710615237A CN107226682A CN 107226682 A CN107226682 A CN 107226682A CN 201710615237 A CN201710615237 A CN 201710615237A CN 107226682 A CN107226682 A CN 107226682A
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王虎
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Hefei Ming Yu High Temperature Technology Co Ltd
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Abstract

本发明公开了一种高温耐火陶瓷,包括如下重量份的原料:白云石15~25份、方镁石20~40份、二氧化硅8~17份、瓷化粉4~9份、膨润土5~10份、高岭土7~12份、改性凹凸棒石粘土14~25份、碎玻璃3~12份、珍珠岩6~13份、石棉粉4~9份、纳米氧化铝3~9份、氧化锆2~8份、骨料4~10份、聚酯纤维2~4份、聚甲基丙烯酸羟乙酯2~5份、固化剂10~20份。本发明所述高温耐火陶瓷具有耐高温性能优异,耐火度高达1200℃以上,且强度高,收缩率低,耐酸碱腐蚀,耐老化,可以应用于温度较高的特殊场合,市场前景广阔。

Description

一种高温耐火陶瓷及其制备方法
技术领域
本发明属于高温耐火材料技术领域,具体涉及一种高温耐火陶瓷及其制备方法。
背景技术
陶瓷砖是由粘土、石英砂以及其他无机非金属原料,经配料、球磨、制粉、成型、烧结等工艺生产的板状或块状陶瓷制品,广泛应用于装饰与保护建筑物、构筑物的墙面和地面。随着房地产业的迅速发展,使得瓷砖的生产和消费都获得了较大的发展。目前市场上的陶瓷砖耐火性较差,超过1000℃,容易出现脱落现象,无法使用于温度较高的特殊场合。
发明内容
本发明提供了一种高温耐火陶瓷及其制备方法,解决了上述背景技术中的问题,本发明所述高温耐火陶瓷具有耐高温性能优异,耐火度高达1200℃以上,且强度高,收缩率低,耐酸碱腐蚀,耐老化,可以应用于温度较高的特殊场合,市场前景广阔。
为了解决现有技术存在的问题,采用如下技术方案:
一种高温耐火陶瓷,包括如下重量份的原料:白云石15~25份、方镁石20~40份、二氧化硅8~17份、瓷化粉4~9份、膨润土5~10份、高岭土7~12份、改性凹凸棒石粘土14~25份、碎玻璃3~12份、珍珠岩6~13份、石棉粉4~9份、纳米氧化铝3~9份、氧化锆2~8份、骨料4~10份、聚酯纤维2~4份、聚甲基丙烯酸羟乙酯2~5份、固化剂10~20份。
优选的,所述高温耐火陶瓷,包括如下重量份的原料:白云石18~22份、方镁石25~35份、二氧化硅10~15份、瓷化粉5~8份、膨润土7~9份、高岭土8~11份、改性凹凸棒石粘土18~22份、碎玻璃6~10份、珍珠岩9~12份、石棉粉5~8份、纳米氧化铝5~7份、氧化锆4~7份、骨料6~9份、聚酯纤维2.5~3.4份、聚甲基丙烯酸羟乙酯3~4份、固化剂13~18份。
优选的,所述高温耐火陶瓷,包括如下重量份的原料:白云石20份、方镁石30份、二氧化硅13份、瓷化粉7份、膨润土8份、高岭土10份、改性凹凸棒石粘土21份、碎玻璃7份、珍珠岩10份、石棉粉7份、纳米氧化铝6份、氧化锆5份、骨料8份、聚酯纤维3.3份、聚甲基丙烯酸羟乙酯3.6份、固化剂14份。
优选的,所述固化剂为硅酸铝、硫酸铝中的任一种或两种的混合物。
优选的,所述骨料选自碳化硅、氮化硅、碳氧化硅、碳氮氧化硅的任一种。
优选的,所述改性凹凸棒石粘土由以下方法制得:将凹凸棒石粘土粉碎至颗粒大小至粒径≤1mm,然后浸没到清水中,用电动搅拌机搅拌8~17min,转速设定为350~450r/min,然后过滤将溶质浸没到无机稀酸溶液中水浴热处理100~150分钟,温度设定在75~95℃之间,再向酸化后的悬浮液中加入分散剂焦磷酸钠充分搅拌,协同超声水热法处理2~3小时后,最后对其进行离心处理,离心之后,取上层悬浮液经过过滤、干燥后输送到回转式烘干炉内焙烧1~2小时即可,焙烧温度为300~400℃。
一种制备所述高温耐火陶瓷的方法,包括如下步骤:
(1)按上述配方称取白云石、方镁石、二氧化硅、瓷化粉、膨润土、高岭土、改性凹凸棒石粘土、碎玻璃、珍珠岩、石棉粉、纳米氧化铝、氧化锆、骨料、聚酯纤维、聚甲基丙烯酸羟乙酯、固化剂,备用;
(2)将白云石、方镁石、二氧化硅、碎玻璃及骨料混合均匀,粉碎,湿法球磨4~8小时,烘干后进行熔炼,待其完全熔化后,搅拌3~7分钟后进行快速水淬,得到破碎的颗粒,湿法球磨5~10小时,烘干,过100~200目筛,备用;
(3)将瓷化粉、膨润土、高岭土、改性凹凸棒石粘土及珍珠岩混合均匀,粉碎,湿法球磨3~6小时,过100~200目筛,静置5~8小时,喷雾干燥成含水量为4~8%的颗粒,备用;
(4)将步骤(2)制得的产物与步骤(3)所得的产物混合均匀,再加入剩余原料混合5~10分钟,得混合母料;
(5)将步骤(4)制得的混合母料置于成型机中压制成型,然后进行干燥,得干坯;
(6)将干坯以8~13℃/min的速率升温至800~900℃,保温2~3小时,再以3~6℃/min的速率升温至1100~1200℃,保温1~2小时,然后以10~20℃/min的速率降温至750~800℃,保温40~80分钟,冷却至常温,磨边,即得所述高温耐火陶瓷。
优选的,所述步骤(5)中压制成型的压力为50~70MPa。
本发明与现有技术相比,其具有以下有益效果:
本发明所述的高温耐火陶瓷采用白云石、方镁石、二氧化硅、瓷化粉作为原料,原料中相互协同作用,制备出的高温耐火陶瓷具有耐高温性能优异,耐火度高达1200℃以上;本发明所述的高温耐火陶瓷原料中还添加了改性凹凸棒石粘土,改性凹凸棒石粘土和其他原料相互配合,有效改善了所述高温耐火陶瓷的耐酸耐腐蚀性和耐老化性,延长其使用寿命,扩大其使用场合。本发明所述的高温耐火陶瓷具有孔径细小、分布均匀的特点,在相同密度下,该材料具有更好的隔热性、更高的强度、良好的抗侵蚀性以及,收缩率低,市场前景广阔。
具体实施方式
下面结合具体实施例,进一步阐述本发明。这些实施例仅用于说明本发明而不用于限制本发明的范围。
实施例1
本实施例涉及一种高温耐火陶瓷,包括如下重量份的原料:白云石15份、方镁石20份、二氧化硅8份、瓷化粉4份、膨润土5份、高岭土7份、改性凹凸棒石粘土14份、碎玻璃3份、珍珠岩6份、石棉粉4份、纳米氧化铝3份、氧化锆2份、骨料4份、聚酯纤维2份、聚甲基丙烯酸羟乙酯2份、固化剂10份。
其中,所述固化剂为硅酸铝。
其中,所述骨料选自碳化硅。
其中,所述改性凹凸棒石粘土由以下方法制得:将凹凸棒石粘土粉碎至颗粒大小至粒径≤1mm,然后浸没到清水中,用电动搅拌机搅拌8min,转速设定为350r/min,然后过滤将溶质浸没到无机稀酸溶液中水浴热处理100分钟,温度设定在75℃之间,再向酸化后的悬浮液中加入分散剂焦磷酸钠充分搅拌,协同超声水热法处理2小时后,最后对其进行离心处理,离心之后,取上层悬浮液经过过滤、干燥后输送到回转式烘干炉内焙烧1小时即可,焙烧温度为300℃。
一种制备所述高温耐火陶瓷的方法,包括如下步骤:
(1)按上述配方称取白云石、方镁石、二氧化硅、瓷化粉、膨润土、高岭土、改性凹凸棒石粘土、碎玻璃、珍珠岩、石棉粉、纳米氧化铝、氧化锆、骨料、聚酯纤维、聚甲基丙烯酸羟乙酯、固化剂,备用;
(2)将白云石、方镁石、二氧化硅、碎玻璃及骨料混合均匀,粉碎,湿法球磨4小时,烘干后进行熔炼,待其完全熔化后,搅拌3分钟后进行快速水淬,得到破碎的颗粒,湿法球磨5小时,烘干,过100~200目筛,备用;
(3)将瓷化粉、膨润土、高岭土、改性凹凸棒石粘土及珍珠岩混合均匀,粉碎,湿法球磨3小时,过100~200目筛,静置5小时,喷雾干燥成含水量为4%的颗粒,备用;
(4)将步骤(2)制得的产物与步骤(3)所得的产物混合均匀,再加入剩余原料混合5分钟,得混合母料;
(5)将步骤(4)制得的混合母料置于成型机中压制成型,然后进行干燥,得干坯;
(6)将干坯以8℃/min的速率升温至800℃,保温2小时,再以3℃/min的速率升温至1100℃,保温1小时,然后以10℃/min的速率降温至750℃,保温40分钟,冷却至常温,磨边,即得所述高温耐火陶瓷。
其中,所述步骤(5)中压制成型的压力为50MPa。
实施例2
本实施例涉及一种高温耐火陶瓷,包括如下重量份的原料:白云石25份、方镁石40份、二氧化硅17份、瓷化粉9份、膨润土10份、高岭土12份、改性凹凸棒石粘土25份、碎玻璃12份、珍珠岩13份、石棉粉9份、纳米氧化铝9份、氧化锆8份、骨料10份、聚酯纤维4份、聚甲基丙烯酸羟乙酯5份、固化剂20份。
其中,所述固化剂为硫酸铝。
其中,所述骨料选自氮化硅。
其中,所述改性凹凸棒石粘土由以下方法制得:将凹凸棒石粘土粉碎至颗粒大小至粒径≤1mm,然后浸没到清水中,用电动搅拌机搅拌17min,转速设定为450r/min,然后过滤将溶质浸没到无机稀酸溶液中水浴热处理150分钟,温度设定在95℃之间,再向酸化后的悬浮液中加入分散剂焦磷酸钠充分搅拌,协同超声水热法处理3小时后,最后对其进行离心处理,离心之后,取上层悬浮液经过过滤、干燥后输送到回转式烘干炉内焙烧2小时即可,焙烧温度为400℃。
一种制备所述高温耐火陶瓷的方法,包括如下步骤:
(1)按上述配方称取白云石、方镁石、二氧化硅、瓷化粉、膨润土、高岭土、改性凹凸棒石粘土、碎玻璃、珍珠岩、石棉粉、纳米氧化铝、氧化锆、骨料、聚酯纤维、聚甲基丙烯酸羟乙酯、固化剂,备用;
(2)将白云石、方镁石、二氧化硅、碎玻璃及骨料混合均匀,粉碎,湿法球磨8小时,烘干后进行熔炼,待其完全熔化后,搅拌7分钟后进行快速水淬,得到破碎的颗粒,湿法球磨10小时,烘干,过100~200目筛,备用;
(3)将瓷化粉、膨润土、高岭土、改性凹凸棒石粘土及珍珠岩混合均匀,粉碎,湿法球磨6小时,过100~200目筛,静置8小时,喷雾干燥成含水量为8%的颗粒,备用;
(4)将步骤(2)制得的产物与步骤(3)所得的产物混合均匀,再加入剩余原料混合10分钟,得混合母料;
(5)将步骤(4)制得的混合母料置于成型机中压制成型,然后进行干燥,得干坯;
(6)将干坯以13℃/min的速率升温至900℃,保温3小时,再以6℃/min的速率升温至1200℃,保温2小时,然后以20℃/min的速率降温至800℃,保温80分钟,冷却至常温,磨边,即得所述高温耐火陶瓷。
其中,所述步骤(5)中压制成型的压力为70MPa。
实施例3
本实施例涉及一种高温耐火陶瓷,包括如下重量份的原料:白云石18份、方镁石25份、二氧化硅10份、瓷化粉5份、膨润土7份、高岭土8份、改性凹凸棒石粘土18份、碎玻璃6份、珍珠岩9份、石棉粉5份、纳米氧化铝5份、氧化锆4份、骨料6份、聚酯纤维2.5份、聚甲基丙烯酸羟乙酯3份、固化剂13份。
其中,所述固化剂为硅酸铝和硫酸铝的混合物。
其中,所述骨料选自碳氧化硅。
其中,所述改性凹凸棒石粘土由以下方法制得:将凹凸棒石粘土粉碎至颗粒大小至粒径≤1mm,然后浸没到清水中,用电动搅拌机搅拌10min,转速设定为380r/min,然后过滤将溶质浸没到无机稀酸溶液中水浴热处理110分钟,温度设定在77℃之间,再向酸化后的悬浮液中加入分散剂焦磷酸钠充分搅拌,协同超声水热法处理2.3小时后,最后对其进行离心处理,离心之后,取上层悬浮液经过过滤、干燥后输送到回转式烘干炉内焙烧1.2小时即可,焙烧温度为330℃。
一种制备所述高温耐火陶瓷的方法,包括如下步骤:
(1)按上述配方称取白云石、方镁石、二氧化硅、瓷化粉、膨润土、高岭土、改性凹凸棒石粘土、碎玻璃、珍珠岩、石棉粉、纳米氧化铝、氧化锆、骨料、聚酯纤维、聚甲基丙烯酸羟乙酯、固化剂,备用;
(2)将白云石、方镁石、二氧化硅、碎玻璃及骨料混合均匀,粉碎,湿法球磨5小时,烘干后进行熔炼,待其完全熔化后,搅拌4分钟后进行快速水淬,得到破碎的颗粒,湿法球磨6小时,烘干,过100~200目筛,备用;
(3)将瓷化粉、膨润土、高岭土、改性凹凸棒石粘土及珍珠岩混合均匀,粉碎,湿法球磨3.5小时,过100~200目筛,静置5~8小时,喷雾干燥成含水量为5%的颗粒,备用;
(4)将步骤(2)制得的产物与步骤(3)所得的产物混合均匀,再加入剩余原料混合6分钟,得混合母料;
(5)将步骤(4)制得的混合母料置于成型机中压制成型,然后进行干燥,得干坯;
(6)将干坯以9℃/min的速率升温至820℃,保温2.2小时,再以4℃/min的速率升温至1110℃,保温1.3小时,然后以11℃/min的速率降温至760℃,保温45分钟,冷却至常温,磨边,即得所述高温耐火陶瓷。
其中,所述步骤(5)中压制成型的压力为55MPa。
实施例4
本实施例涉及一种高温耐火陶瓷,包括如下重量份的原料:白云石22份、方镁石35份、二氧化硅15份、瓷化粉8份、膨润土9份、高岭土11份、改性凹凸棒石粘土22份、碎玻璃10份、珍珠岩12份、石棉粉8份、纳米氧化铝7份、氧化锆7份、骨料9份、聚酯纤维3.4份、聚甲基丙烯酸羟乙酯4份、固化剂18份。
其中,所述固化剂为硅酸铝、硫酸铝的混合物。
其中,所述骨料选自碳氮氧化硅。
其中,所述改性凹凸棒石粘土由以下方法制得:将凹凸棒石粘土粉碎至颗粒大小至粒径≤1mm,然后浸没到清水中,用电动搅拌机搅拌12min,转速设定为400r/min,然后过滤将溶质浸没到无机稀酸溶液中水浴热处理125分钟,温度设定在85℃之间,再向酸化后的悬浮液中加入分散剂焦磷酸钠充分搅拌,协同超声水热法处理2.5小时后,最后对其进行离心处理,离心之后,取上层悬浮液经过过滤、干燥后输送到回转式烘干炉内焙烧1.5小时即可,焙烧温度为350℃。
一种制备所述高温耐火陶瓷的方法,包括如下步骤:
(1)按上述配方称取白云石、方镁石、二氧化硅、瓷化粉、膨润土、高岭土、改性凹凸棒石粘土、碎玻璃、珍珠岩、石棉粉、纳米氧化铝、氧化锆、骨料、聚酯纤维、聚甲基丙烯酸羟乙酯、固化剂,备用;
(2)将白云石、方镁石、二氧化硅、碎玻璃及骨料混合均匀,粉碎,湿法球磨6小时,烘干后进行熔炼,待其完全熔化后,搅拌5分钟后进行快速水淬,得到破碎的颗粒,湿法球磨8小时,烘干,过100~200目筛,备用;
(3)将瓷化粉、膨润土、高岭土、改性凹凸棒石粘土及珍珠岩混合均匀,粉碎,湿法球磨5小时,过100~200目筛,静置6小时,喷雾干燥成含水量为6%的颗粒,备用;
(4)将步骤(2)制得的产物与步骤(3)所得的产物混合均匀,再加入剩余原料混合7分钟,得混合母料;
(5)将步骤(4)制得的混合母料置于成型机中压制成型,然后进行干燥,得干坯;
(6)将干坯以11℃/min的速率升温至850℃,保温2.5小时,再以5℃/min的速率升温至1150℃,保温1.5小时,然后以15℃/min的速率降温至780℃,保温60分钟,冷却至常温,磨边,即得所述高温耐火陶瓷。
其中,所述步骤(5)中压制成型的压力为62MPa。
实施例5
本实施例涉及一种高温耐火陶瓷,包括如下重量份的原料:白云石20份、方镁石30份、二氧化硅13份、瓷化粉7份、膨润土8份、高岭土10份、改性凹凸棒石粘土21份、碎玻璃7份、珍珠岩10份、石棉粉7份、纳米氧化铝6份、氧化锆5份、骨料8份、聚酯纤维3.3份、聚甲基丙烯酸羟乙酯3.6份、固化剂14份。
其中,所述固化剂为硅酸铝、硫酸铝的混合物。
其中,所述骨料选自碳氧化硅。
其中,所述改性凹凸棒石粘土由以下方法制得:将凹凸棒石粘土粉碎至颗粒大小至粒径≤1mm,然后浸没到清水中,用电动搅拌机搅拌14min,转速设定为420r/min,然后过滤将溶质浸没到无机稀酸溶液中水浴热处理140分钟,温度设定在90℃之间,再向酸化后的悬浮液中加入分散剂焦磷酸钠充分搅拌,协同超声水热法处理2.7小时后,最后对其进行离心处理,离心之后,取上层悬浮液经过过滤、干燥后输送到回转式烘干炉内焙烧1.8小时即可,焙烧温度为370℃。
一种制备所述高温耐火陶瓷的方法,包括如下步骤:
(1)按上述配方称取白云石、方镁石、二氧化硅、瓷化粉、膨润土、高岭土、改性凹凸棒石粘土、碎玻璃、珍珠岩、石棉粉、纳米氧化铝、氧化锆、骨料、聚酯纤维、聚甲基丙烯酸羟乙酯、固化剂,备用;
(2)将白云石、方镁石、二氧化硅、碎玻璃及骨料混合均匀,粉碎,湿法球磨7小时,烘干后进行熔炼,待其完全熔化后,搅拌6分钟后进行快速水淬,得到破碎的颗粒,湿法球磨8小时,烘干,过100~200目筛,备用;
(3)将瓷化粉、膨润土、高岭土、改性凹凸棒石粘土及珍珠岩混合均匀,粉碎,湿法球磨5小时,过100~200目筛,静置7小时,喷雾干燥成含水量为7%的颗粒,备用;
(4)将步骤(2)制得的产物与步骤(3)所得的产物混合均匀,再加入剩余原料混合9分钟,得混合母料;
(5)将步骤(4)制得的混合母料置于成型机中压制成型,然后进行干燥,得干坯;
(6)将干坯以12℃/min的速率升温至890℃,保温2.8小时,再以5℃/min的速率升温至1180℃,保温1.8小时,然后以19℃/min的速率降温至790℃,保温70分钟,冷却至常温,磨边,即得所述高温耐火陶瓷。
其中,所述步骤(5)中压制成型的压力为65MPa。
以上对本发明的具体实施例进行了描述。需要理解的是,本发明并不局限于上述特定实施方式,本领域技术人员可以在权利要求的范围内做出各种变形或修改,这并不影响本发明的实质内容。

Claims (8)

1.一种高温耐火陶瓷,其特征在于,包括如下重量份的原料:白云石15~25份、方镁石20~40份、二氧化硅8~17份、瓷化粉4~9份、膨润土5~10份、高岭土7~12份、改性凹凸棒石粘土14~25份、碎玻璃3~12份、珍珠岩6~13份、石棉粉4~9份、纳米氧化铝3~9份、氧化锆2~8份、骨料4~10份、聚酯纤维2~4份、聚甲基丙烯酸羟乙酯2~5份、固化剂10~20份。
2.根据权利要求1所述的高温耐火陶瓷,其特征在于,包括如下重量份的原料:白云石18~22份、方镁石25~35份、二氧化硅10~15份、瓷化粉5~8份、膨润土7~9份、高岭土8~11份、改性凹凸棒石粘土18~22份、碎玻璃6~10份、珍珠岩9~12份、石棉粉5~8份、纳米氧化铝5~7份、氧化锆4~7份、骨料6~9份、聚酯纤维2.5~3.4份、聚甲基丙烯酸羟乙酯3~4份、固化剂13~18份。
3.根据权利要求1所述的高温耐火陶瓷,其特征在于,包括如下重量份的原料:白云石20份、方镁石30份、二氧化硅13份、瓷化粉7份、膨润土8份、高岭土10份、改性凹凸棒石粘土21份、碎玻璃7份、珍珠岩10份、石棉粉7份、纳米氧化铝6份、氧化锆5份、骨料8份、聚酯纤维3.3份、聚甲基丙烯酸羟乙酯3.6份、固化剂14份。
4.根据权利要求1所述的高温耐火陶瓷,其特征在于,所述固化剂为硅酸铝、硫酸铝中的任一种或两种的混合物。
5.根据权利要求1所述的高温耐火陶瓷,其特征在于,所述骨料选自碳化硅、氮化硅、碳氧化硅、碳氮氧化硅的任一种。
6.根据权利要求1所述的高温耐火陶瓷,其特征在于,所述改性凹凸棒石粘土由以下方法制得:将凹凸棒石粘土粉碎至颗粒大小至粒径≤1mm,然后浸没到清水中,用电动搅拌机搅拌8~17min,转速设定为350~450r/min,然后过滤将溶质浸没到无机稀酸溶液中水浴热处理100~150分钟,温度设定在75~95℃之间,再向酸化后的悬浮液中加入分散剂焦磷酸钠充分搅拌,协同超声水热法处理2~3小时后,最后对其进行离心处理,离心之后,取上层悬浮液经过过滤、干燥后输送到回转式烘干炉内焙烧1~2小时即可,焙烧温度为300~400℃。
7.一种制备权利要求1~6任一项所述高温耐火陶瓷的方法,其特征在于,包括如下步骤:
(1)按上述配方称取白云石、方镁石、二氧化硅、瓷化粉、膨润土、高岭土、改性凹凸棒石粘土、碎玻璃、珍珠岩、石棉粉、纳米氧化铝、氧化锆、骨料、聚酯纤维、聚甲基丙烯酸羟乙酯、固化剂,备用;
(2)将白云石、方镁石、二氧化硅、碎玻璃及骨料混合均匀,粉碎,湿法球磨4~8小时,烘干后进行熔炼,待其完全熔化后,搅拌3~7分钟后进行快速水淬,得到破碎的颗粒,湿法球磨5~10小时,烘干,过100~200目筛,备用;
(3)将瓷化粉、膨润土、高岭土、改性凹凸棒石粘土及珍珠岩混合均匀,粉碎,湿法球磨3~6小时,过100~200目筛,静置5~8小时,喷雾干燥成含水量为4~8%的颗粒,备用;
(4)将步骤(2)制得的产物与步骤(3)所得的产物混合均匀,再加入剩余原料混合5~10分钟,得混合母料;
(5)将步骤(4)制得的混合母料置于成型机中压制成型,然后进行干燥,得干坯;
(6)将干坯以8~13℃/min的速率升温至800~900℃,保温2~3小时,再以3~6℃/min的速率升温至1100~1200℃,保温1~2小时,然后以10~20℃/min的速率降温至750~800℃,保温40~80分钟,冷却至常温,磨边,即得所述高温耐火陶瓷。
8.根据权利要求7所述的制备方法,其特征在于,所述步骤(5)中压制成型的压力为50~70MPa。
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