CN107235719A - 一种高韧性耐火材料 - Google Patents
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Abstract
本发明属于耐火材料技术领域。本发明公开了高韧性耐火材料,其主要由以下重量份的原料制得:氧化铝100份,氧化镁30~40份,五氧化二铌1~2份,五氧化二钽0.5~1份,粉料粘结剂1~3份,成型粘结剂0.2~0.5份。本发明中,在制备耐火材料过程中,制得的生坯具有较好的机械性能,不易发生破碎等问题,良品率较高;本发明制得而得的耐火具有较高的断裂韧性,能够保证耐火材料的使用寿命,同时也能保证耐火材料的可靠性。
Description
技术领域
本发明涉及耐火材料技术领域,尤其是涉及一种高韧性耐火材料。
背景技术
在传统意义上,耐火材料是指耐火度不低于1580℃的无机非金属材料,它是为高温技术服务的基础材料,是用作高温窑炉等热工设备的结构材料,以及工业高温容器和部件的材料,并且能够承受相应的物理化学变化及机械作用。
大部分耐火材料是以天然矿石(如耐火粘土、硅石、菱镁矿、白云石)为原料制造的,采用某些工业原料和人工合成原料(如工业氧化铝、碳化硅、合成莫来石、合成尖晶石等)也日益增多,因此,耐火材料的种类很多。耐火材料按照矿物组成可以分为氧化硅质、硅酸铝质、镁质、白云石质、橄榄石质、尖晶石质、含碳质、含锆质耐火材料及特殊耐火材料;按照制造方法可以分为天然矿石和人造制品;按其方式可分为块状制品和不定形耐火材料;按照热处理方式可分为不烧制品、烧成制品和熔铸制品;按照耐火度可分为普通、高级和特级耐火制品;按照化学性质可分为酸性、中性及碱性耐火材料;按照其密度可分为轻质及重质耐火材料;按照其制品的形状和尺寸可分为标准砖、异形砖、特异形砖、管和耐火器皿;还可以按其应用分为高炉用、水泥窑用、玻璃窑用、陶瓷窑用耐火材料等。
无机非金属材料的机械韧性较差是无机非金属和材料中普遍存在的一个问题,作为同属无机非金属材料的耐火材料,其机械韧性也较差,虽然在使用过程中耐火材料几乎不需要进行移动,但是其较差的机械韧性也影响到了其高温时候的抗热震性能,在急冷急热和使用的间隙由于较大的温差耐火材料极易在热胀冷缩作用下发生开裂、剥落等影响耐火材料完整性的情况,降低了耐火材料的使用寿命;同时对于那些需要经常进行移动的耐火材料制品,其较差的机械韧性则会大大增加耐火制品的损坏率,影响其日常使用。
发明内容
为解决上述问题,本发明提供了一种具有较高耐火度并且具有优良断裂韧性的高韧性耐火材料,同时其制备过程中的生坯具有较高的机械强度。
为实现上述目的,本发明采用的技术方案如下:
一种高韧性耐火材料,主要由以下重量份的原料制得:
氧化铝100份,氧化镁30~40份,五氧化二铌1~2份,五氧化二钽0.5~1份,粉料粘结剂1~3份,成型粘结剂0.2~0.5份。
在耐火材料体系中,镁铝尖晶石系耐火材料是一种重要的耐火材料。当氧化镁和氧化铝原料粉体中氧化铝的摩尔百分比为50%左右时,经高温处理后会生成稳定的并具有极好耐高温性能的镁铝尖晶石物相,同时氧化铝含量越高,镁铝尖晶石相更稳定;由于氧化铝,特别是高纯氧化铝的成本是氧化镁的两倍甚至更多,因此在保证能够生成稳定镁铝尖晶石相的前提下尽量减少氧化铝的添加量;本发明中氧化铝的摩尔百分比在49.75~56.90%范围内,经后续高温处理后能够生成足量并稳定存在的镁铝尖晶石相,并能尽量降低生产成本。
铌元素和钽元素是元素周期表第VB族的元素,在元素周期表中这两个元素上下紧挨,具有相类的性质,同样其氧化物,五氧化二铌和五氧化二钽也具有相类的物理及化学性质;针对于本发明,五氧化二钽和五氧化二铌具有三个重要的特性,1.具有一定的耐高温性能,添加到耐火材料中虽然是作为一种功能添加剂,即作为增韧剂添加,但是不会对耐火材料的耐火度产生较大的影响;2.这两种氧化物具有较稳定的性质,或者说在本发明的体系中较稳定,不会与氧化镁或者氧化铝等产生反应,也不会发生固溶,能够独立的存在并起到增韧作用;3.该两种氧化物颗粒都具有良好的机械力学性能,也即具有较好的拉伸性能,其添加后不仅能实现传统的颗粒增韧的效果,还能使这种效果发挥到最佳,能够更好的抑制材料内裂纹的扩散。但是这两种氧化物也存在一定的问题,即五氧化二钽虽然具有好的耐高温性能,但是其拉伸性能较差,而五氧化二钽虽然耐高温性能略差,但是拉伸性能还不错,因此需要将两者按一定不利混合后进行添加,而五氧化二铌占多数的配合方法对耐火材料的增韧效果更佳。
作为优选,氧化铝和氧化镁的粒径为4000~5000目。
作为优选,粉料粘结剂为5wt%的聚偏氟乙烯N-甲基吡咯烷酮溶液。
聚偏氟乙烯N-甲基吡咯烷酮溶液是指聚偏氟乙烯溶于N-甲基吡咯烷酮中获得的溶液。
本发明中的粉料粘结剂用于将由五氧化二铌和五氧化二钽组成的增韧剂均匀的粘结到经造粒后的氧化镁和氧化铝粉体上。现有技术中,粘结剂一般采用聚乙烯醇(PVA)水溶液,但是聚乙烯醇是一种不耐高温的有机高分子化合物,其熔点较低,分解温度也较低,作为粘结剂添加到粉体中,在烧结阶段需要在较低的温度下进行排胶处理,在较低的温度下排胶,容易造成粘结剂分解后的产物在粉料中的滞留时间过程,甚至对粉体产生较长时间持续的冲击,造成制得的耐火材料力学性能的下降;聚偏氟乙烯是一种具有耐高温特性的有机高分子化合物,相较于聚乙烯醇,其具有相对更高的熔点,相对更高的分解温度,因此粉料排胶的温度也可以相应的升高,排胶温度升高后,分解产物也能更快地从粉体中排出,减少滞留粉体的时间,减少对制得耐火材料力学性能的影响。
作为优选,成型粘结剂为5wt%的聚乙烯醇乙醇溶液。
聚乙烯醇乙醇溶液是指将聚乙烯醇溶于乙醇中获得的溶液。
因为本发明中的粉料粘结剂在经过制备后全部位于颗粒内部,难以实现较好的颗粒间粘结,因此需要在加入成型粘结剂,由于只需起到颗粒之间的粘结作用,用量不必太多,添加0.1wt%左右即可实现颗粒间的粘结作用。
因此,本发明具有以下有益效果:
(1)本发明中,在制备耐火材料过程中,制得的生坯具有较好的机械性能,不易发生破碎等问题,良品率较高;
(2)本发明制得而得的耐火材料具有较高的断裂韧性,能够保证耐火材料的使用寿命,同时也能保证耐火材料的可靠性。
具体实施方式
下面结合具体实施方式对本发明的技术方案作进一步的说明。
显然,所描述的实施例仅是本发明的一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其它实施例,都属于本发明保护的范围。
实施例1
一种高韧性耐火材料,主要由以下重量份的原料制得:
氧化铝100份,氧化镁30份,五氧化二铌1份,五氧化二钽0.5份,粉料粘结剂1份,成型粘结剂0.2份;氧化铝和氧化镁的粒径为4000目,粉料粘结剂为5wt%的聚偏氟乙烯N-甲基吡咯烷酮溶液,成型粘结剂为5wt%的聚乙烯醇乙醇溶液;
将上述原料均匀混合成型并在1400℃下烧结8小时制得高韧性耐火材料。
实施例2
一种高韧性耐火材料,主要由以下重量份的原料制得:
氧化铝100份,氧化镁32份,五氧化二铌1.5份,五氧化二钽1份,粉料粘结剂1.5份,成型粘结剂0.4份;氧化铝和氧化镁的粒径为4000目,粉料粘结剂为5wt%的聚偏氟乙烯N-甲基吡咯烷酮溶液,成型粘结剂为5wt%的聚乙烯醇乙醇溶液;
将上述原料均匀混合成型并在1400℃下烧结8小时制得高韧性耐火材料。
实施例3
一种高韧性耐火材料,主要由以下重量份的原料制得:
氧化铝100份,氧化镁35份,五氧化二铌.5份,五氧化二钽0.75份,粉料粘结剂2份,成型粘结剂0.35份;氧化铝和氧化镁的粒径为4500目,粉料粘结剂为5wt%的聚偏氟乙烯N-甲基吡咯烷酮溶液,成型粘结剂为5wt%的聚乙烯醇乙醇溶液;
将上述原料均匀混合成型并在1400℃下烧结8小时制得高韧性耐火材料。
实施例4
一种高韧性耐火材料,主要由以下重量份的原料制得:
氧化铝100份,氧化镁38份,五氧化二铌1.8份,五氧化二钽0.6份,粉料粘结剂2.5份,成型粘结剂0.25份;氧化铝和氧化镁的粒径为5000目,粉料粘结剂为5wt%的聚偏氟乙烯N-甲基吡咯烷酮溶液,成型粘结剂为5wt%的聚乙烯醇乙醇溶液;
将上述原料均匀混合成型并在1400℃下烧结8小时制得高韧性耐火材料。
实施例5
一种高韧性耐火材料,主要由以下重量份的原料制得:
氧化铝100份,氧化镁40份,五氧化二铌2份,五氧化二钽1份,粉料粘结剂3份,成型粘结剂0.5份;氧化铝和氧化镁的粒径为5000目,粉料粘结剂为5wt%的聚偏氟乙烯N-甲基吡咯烷酮溶液,成型粘结剂为5wt%的聚乙烯醇乙醇溶液;
将上述原料均匀混合成型并在1400℃下烧结8小时制得高韧性耐火材料。
效果测试:
将上述实施例中制得高韧性耐火材料进行相关性能测试;
耐火度测试采用GB/T 7322-2007记载的方法进行,显气孔率采用GB/T 5071-2013记载的方法进行,常温耐压强度采用GB/T 5072-2008记载的方法进行,荷重软化温度采用GB/T5989-2008记载的方法进行,断裂韧性采用本领域公知的SENB法进行测试。
测试效果:
1.耐火度≥1850℃,最大使用温度≥1800℃;
2.显气孔率≤6%;
3.常温耐压强度≥118MPa;
4.荷重软化温度≥1850℃;
5.断裂韧性≥1.4MPa·m1/2。
应当理解的是,对于本领域普通技术人员来说,可以根据上述说明加以改进或变换,而所有这些改进和变换都应属于本发明所附权利要求的保护范围。
Claims (4)
1.一种高韧性耐火材料,其特征在于主要由以下重量份的原料制得:
氧化铝100份,氧化镁30~40份,五氧化二铌1~2份,五氧化二钽0.5~1份,粉料粘结剂1~3份,成型粘结剂0.2~0.5份。
2.根据权利要求1所述的一种高韧性耐火材料,其特征在于:
所述的氧化铝和氧化镁的粒径为4000~5000目。
3.根据权利要求1所述的一种高韧性耐火材料,其特征在于:
所述的粉料粘结剂为5wt%的聚偏氟乙烯N-甲基吡咯烷酮溶液。
4.根据权利要求1所述的一种高韧性耐火材料,其特征在于:
所述的成型粘结剂为5wt%的聚乙烯醇乙醇溶液。
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