CN107266025A - 一种陶瓷微珠研磨介质的制备方法 - Google Patents

一种陶瓷微珠研磨介质的制备方法 Download PDF

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CN107266025A
CN107266025A CN201710510097.4A CN201710510097A CN107266025A CN 107266025 A CN107266025 A CN 107266025A CN 201710510097 A CN201710510097 A CN 201710510097A CN 107266025 A CN107266025 A CN 107266025A
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fine bead
ceramic fine
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陈合华
薛焱璟
陈春
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Zhou Rong
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Changzhou Kai Heng Textile Co Ltd
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Abstract

本发明涉及一种陶瓷微珠研磨介质的制备方法，属于陶瓷成型技术领域。本发明首先以高岭土、碳化硅、灰钙土等为原料，混合后球磨，得混合粉末；再将混合粉末、水等进行混合球磨，得浆料；向浆料中分别加入鸡蛋蛋清和蔗糖，混合后搅拌得带泡浆料；将带泡浆料进行成球、烧制后得空心陶瓷微珠，将空心陶瓷微珠打磨，得表面粗糙空心微球；再以Fe、Mn、Mo等为原料进行加热熔融，得混合金属液体，将表面粗糙空心微球放入混合金属液中浸泡后取出，自然冷却至室温后，经干燥、抛光即可。本发明制备的陶瓷微珠研磨介质硬度高，耐磨损率低，具有较好的耐磨性能。

Description

一种陶瓷微珠研磨介质的制备方法
技术领域
本发明涉及一种陶瓷微珠研磨介质的制备方法，属于陶瓷成型技术领域。
背景技术
陶瓷研磨介质具备的机械强度大、硬度高、密度大、高温性能好、对物料无污染、耐酸碱腐蚀能力强，耐磨性能优异等优点使其在研磨介质领域中占有非常重要的一席之地，被广泛应用于矿产、化工、涂料油漆、机械电子等相关的精细加工领域。
在我国目前的市面上，陶瓷微珠主要包括氧化铝、氧化锆、碳化硅、氮化硅等品种，其中以ZrO2瓷球和高铝瓷球（75～95％Al2O3）为市场主要供求对象。但是ZrO2和Al2O3价格昂贵，制造成本高，不具市场优势。于是开发Al2O3含量≤60％的中铝瓷，因其生产工艺成熟、生产线投资小、产品性价比高，而成为当今矿产、粉体加工行业的主流用品，用量最大，用途甚广。但目前的原料配方所用的是Al2O3原料，其成本较高，若采用其他原料则制得的中铝瓷微珠研磨介质的耐磨性不高和硬度较低，在研磨过程中易开裂，限制了陶瓷微珠的使用范围。
为此，迫切需要一种耐磨性能好，硬度高的陶瓷微珠研磨介质。
发明内容
本发明所要解决的技术问题：针对传统的陶瓷微珠研磨介质耐磨性能和硬度较低，在研磨过程中易开裂的问题，提供了一种陶瓷微珠研磨介质的制备方法。
为解决上述技术问题，本发明采用的技术方案是：
（1）按重量份数计，选取20～30份高岭土、5～8份碳化硅、10～15份灰钙土、5～10份长石砂岩、3～5份氧化锆、1～3份白云母、1～3份蛇纹石和1～3份砂砾石，混合后加入球磨机中，球磨后出料，得混合粉末；
（2）按重量份数计，选取100～120份混合粉末、50～60份水、3～5份表面活性剂、1～3份分散剂和2～4份羧甲基纤维素，搅拌混合后加入球磨机中，球磨后出料得浆料；
（3）向浆料中分别加入鸡蛋蛋清和蔗糖，混合后以2000～3000r/min转速搅拌3～5min，搅拌后得带泡浆料；
（4）将带泡浆料放入成球机中，制备得陶瓷微珠坯体，将陶瓷微珠坯体放入窑炉中，以1～3℃/min升温速率升温至1400～1500℃，烧制后得空心陶瓷微珠，将空心陶瓷微珠置于陶瓷打磨机中打磨30～60s，得表面粗糙空心微球；
（5）按质量百分比计，选取12～16%Fe、8.0～13.2%Mn、8.3～9.8%Mo、2～12%Cu、7～12%Sb、12～18%Zn、7～12%Al，其余的为Cr，混合后放入石墨粘土坩埚中，再把坩埚放入电阻炉中，在高纯氩气的气氛下加热至1850～2000℃熔融，保温熔融10～20min，得混合金属液体，将表面粗糙空心微球放入混合金属液中浸泡1～3s后立即取出，自然冷却至室温后，放入烘箱中干燥，得干燥物后放入抛光机中，抛光后即可得到陶瓷微珠研磨介质。
步骤（1）中所述的混合粉末的粒径为5～10μm。
步骤（2）中所述的表面活性剂为聚乙二醇月桂酸酯、椰油基羟乙基磺酸钠、十二醇聚氧乙烯醚硫酸钠中的一种或多种。
步骤（2）中所述的分散剂为聚乙烯吡咯烷酮、磷酸酯、聚乙烯醇中的一种或多种。
步骤（3）中所述的鸡蛋蛋清的质量为浆料质量2～4%，蔗糖质量为浆料质量1～3%。
步骤（4）中所述的烧制时间为40～50min。
本发明与其他方法相比，有益技术效果是：
（1）本发明使用高岭土、碳化硅、灰钙土、长石砂岩、氧化锆等物质球磨后得混合粉末，并作为陶瓷微珠介质的原料，一方面可以大量消耗矿石积存、合理利用资源，另一方面制备出的微珠内部是由单个或多个微孔组成，再将混合粉末、水、分散剂和表面活性剂等混合后得浆料，并在浆料中加入蛋清和蔗糖，蛋清和蔗糖作为发泡剂，可制备出质轻且具有一定强度的空心微珠多孔陶瓷材料，并且在烧制时蛋清和蔗糖可以去除，对多孔陶瓷微珠的性能无影响；
（2）本发明将铁、锰、钴等金属元素熔融后得混合金属液，将多孔陶瓷浸入金属混合液中，金属混合液可进入多孔陶瓷孔隙中，可以有效提高陶瓷微珠研磨介质耐磨性能和硬度，在研磨过程中不会产生开裂，降低陶瓷微珠研磨介质的磨损率。
具体实施方式
按重量份数计，选取20～30份高岭土、5～8份碳化硅、10～15份灰钙土、5～10份长石砂岩、3～5份氧化锆、1～3份白云母、1～3份蛇纹石和1～3份砂砾石，混合后加入球磨机中，球磨后出料，得混合粉末，混合粉末的粒径为5～10μm；按重量份数计，选取100～120份混合粉末、50～60份水、3～5份表面活性剂、1～3份分散剂和2～4份羧甲基纤维素，搅拌混合后加入球磨机中，球磨3～5h后出料得浆料；向浆料中分别加入浆料质量2～4%鸡蛋蛋清和浆料质量1～3%蔗糖，混合后以2000～3000r/min转速搅拌3～5min，搅拌后得带泡浆料；将带泡浆料放入成球机中，制备得陶瓷微珠坯体，将陶瓷微珠坯体放入窑炉中，以1～3℃/min升温速率升温至1400～1500℃，烧制40～50min后得空心陶瓷微珠，将空心陶瓷微珠置于陶瓷打磨机中打磨30～60s，得表面粗糙空心微球；按质量百分比计，选取12～16%Fe、8.0～13.2%Mn、8.3～9.8%Mo、2～12%Cu、7～12%Sb、12～18%Zn、7～12%Al，其余的为Cr，混合后放入石墨粘土坩埚中，再把坩埚放入电阻炉中，在高纯氩气的气氛下加热至1850～2000℃熔融，保温熔融10～20min，得混合金属液体，将表面粗糙空心微球放入混合金属液中浸泡1～3s后立即取出，自然冷却至室温后，放入烘箱中，升温至100～120℃，干燥8～10h，得干燥物后放入抛光机中，抛光后即可得到陶瓷微珠研磨介质。所述的表面活性剂为聚乙二醇月桂酸酯、椰油基羟乙基磺酸钠、十二醇聚氧乙烯醚硫酸钠中的一种或多种。所述的分散剂为聚乙烯吡咯烷酮、磷酸酯、聚乙烯醇中的一种或多种。
实例1
按重量份数计，选取30份高岭土、8份碳化硅、15份灰钙土、10份长石砂岩、5份氧化锆、3份白云母、3份蛇纹石和3份砂砾石，混合后加入球磨机中，球磨后出料，得混合粉末，混合粉末的粒径为10μm；按重量份数计，选取120份混合粉末、60份水、5份聚乙二醇月桂酸酯、3份聚乙烯吡咯烷酮和4份羧甲基纤维素，搅拌混合后加入球磨机中，球磨5h后出料得浆料；向浆料中分别加入浆料质量4%鸡蛋蛋清和浆料质量3%蔗糖，混合后以3000r/min转速搅拌5min，搅拌后得带泡浆料；将带泡浆料放入成球机中，制备得陶瓷微珠坯体，将陶瓷微珠坯体放入窑炉中，以3℃/min升温速率升温至1500℃，烧制50min后得空心陶瓷微珠，将空心陶瓷微珠置于陶瓷打磨机中打磨60s，得表面粗糙空心微球；按质量百分比计，选取16%Fe、13.2%Mn、9.8%Mo、12%Cu、12%Sb、18%Zn、12%Al，其余的为Cr，混合后放入石墨粘土坩埚中，再把坩埚放入电阻炉中，在高纯氩气的气氛下加热至2000℃熔融，保温熔融20min，得混合金属液体，将表面粗糙空心微球放入混合金属液中浸泡3s后立即取出，自然冷却至室温后，放入烘箱中，升温至120℃，干燥10h，得干燥物后放入抛光机中，抛光后即可得到陶瓷微珠研磨介质。
实例2
按重量份数计，选取20份高岭土、5份碳化硅、10份灰钙土、5份长石砂岩、3份氧化锆、1份白云母、1份蛇纹石和1份砂砾石，混合后加入球磨机中，球磨后出料，得混合粉末，混合粉末的粒径为10μm；按重量份数计，选取120份混合粉末、60份水、5份椰油基羟乙基磺酸钠、3份磷酸酯和4份羧甲基纤维素，搅拌混合后加入球磨机中，球磨5h后出料得浆料；向浆料中分别加入浆料质量4%鸡蛋蛋清和浆料质量3%蔗糖，混合后以3000r/min转速搅拌5min，搅拌后得带泡浆料；将带泡浆料放入成球机中，制备得陶瓷微珠坯体，将陶瓷微珠坯体放入窑炉中，以3℃/min升温速率升温至1500℃，烧制50min后得空心陶瓷微珠，将空心陶瓷微珠置于陶瓷打磨机中打磨60s，得表面粗糙空心微球；按质量百分比计，选取16%Fe、13.2%Mn、9.8%Mo、12%Cu、12%Sb、18%Zn、12%Al，其余的为Cr，混合后放入石墨粘土坩埚中，再把坩埚放入电阻炉中，在高纯氩气的气氛下加热至2000℃熔融，保温熔融20min，得混合金属液体，将表面粗糙空心微球放入混合金属液中浸泡3s后立即取出，自然冷却至室温后，放入烘箱中，升温至120℃，干燥10h，得干燥物后放入抛光机中，抛光后即可得到陶瓷微珠研磨介质。
实例3
按重量份数计，选取25份高岭土、7份碳化硅、12份灰钙土、7份长石砂岩、4份氧化锆、2份白云母、2份蛇纹石和2份砂砾石，混合后加入球磨机中，球磨后出料，得混合粉末，混合粉末的粒径为7μm；按重量份数计，选取110份混合粉末、55份水、4份十二醇聚氧乙烯醚硫酸钠、2份聚乙烯醇和3份羧甲基纤维素，搅拌混合后加入球磨机中，球磨4h后出料得浆料；向浆料中分别加入浆料质量3%鸡蛋蛋清和浆料质量2%蔗糖，混合后以2500r/min转速搅拌4min，搅拌后得带泡浆料；将带泡浆料放入成球机中，制备得陶瓷微珠坯体，将陶瓷微珠坯体放入窑炉中，以2℃/min升温速率升温至1450℃，烧制45min后得空心陶瓷微珠，将空心陶瓷微珠置于陶瓷打磨机中打磨40s，得表面粗糙空心微球；按质量百分比计，选取15%Fe、11.8%Mn、9.6%Mo、10%Cu、8%Sb、16%Zn、10%Al，其余的为Cr，混合后放入石墨粘土坩埚中，再把坩埚放入电阻炉中，在高纯氩气的气氛下加热至1950℃熔融，保温熔融15min，得混合金属液体，将表面粗糙空心微球放入混合金属液中浸泡2s后立即取出，自然冷却至室温后，放入烘箱中，升温至110℃，干燥9h，得干燥物后放入抛光机中，抛光后即可得到陶瓷微珠研磨介质。
对照例：上海某纳米材料有限公司生产的陶瓷微珠。
将实例及对照例的陶瓷微珠进行检测，具体检测如下：
（1）体积密度测试：用阿基米德排水法对陶瓷微珠进行体积密度测试。
（2）硬度测试：使用小负荷维氏硬度计测量陶瓷微珠的维氏硬度。
（3）磨损率测试：用砂磨机作为测试仪器，称取300g陶瓷微珠将其清洗干净后干燥直至恒重，再称取300g碳化硅微粉并加入400g水作为研磨环境，砂磨机转速为3000r/min，研磨15h后，取出陶瓷微珠洗净烘干直至质量恒定。
磨损率计算公式
G0为磨损前陶瓷微珠的质量；
G1为磨损后陶瓷微珠的质量；
T为磨损的测试时间。
具体检测结果如表1。
表1
项目 实例1 实例2 实例3 对照例
体积密度（g/cm3） 3.01 2.98 3.08 2.80
维氏硬度（HV10） 1460 1470 1475 1320
磨损率（g/kg·h） 0.28 0.30 0.31 0.95
由表1可知，本发明制备的陶瓷微珠硬度高，磨损率低，具有较好的耐磨性能。

Claims (6)

1.一种陶瓷微珠研磨介质的制备方法，其特征在于具体制备步骤为：
（1）按重量份数计，选取20～30份高岭土、5～8份碳化硅、10～15份灰钙土、5～10份长石砂岩、3～5份氧化锆、1～3份白云母、1～3份蛇纹石和1～3份砂砾石，混合后加入球磨机中，球磨后出料，得混合粉末；
（2）按重量份数计，选取100～120份混合粉末、50～60份水、3～5份表面活性剂、1～3份分散剂和2～4份羧甲基纤维素，搅拌混合后加入球磨机中，球磨后出料得浆料；
（3）向浆料中分别加入鸡蛋蛋清和蔗糖，混合后以2000～3000r/min转速搅拌3～5min，搅拌后得带泡浆料；
（4）将带泡浆料放入成球机中，制备得陶瓷微珠坯体，将陶瓷微珠坯体放入窑炉中，以1～3℃/min升温速率升温至1400～1500℃，烧制后得空心陶瓷微珠，将空心陶瓷微珠置于陶瓷打磨机中打磨30～60s，得表面粗糙空心微球；
（5）按质量百分比计，选取12～16%Fe、8.0～13.2%Mn、8.3～9.8%Mo、2～12%Cu、7～12%Sb、12～18%Zn、7～12%Al，其余的为Cr，混合后放入石墨粘土坩埚中，再把坩埚放入电阻炉中，在高纯氩气的气氛下加热至1850～2000℃熔融，保温熔融10～20min，得混合金属液体，将表面粗糙空心微球放入混合金属液中浸泡1～3s后立即取出，自然冷却至室温后，放入烘箱中干燥，得干燥物后放入抛光机中，抛光后即可得到陶瓷微珠研磨介质。
2.根据权利要求1所述的一种陶瓷微珠研磨介质的制备方法，其特征在于：步骤（1）中所述的混合粉末的粒径为5～10μm。
3.根据权利要求1所述的一种陶瓷微珠研磨介质的制备方法，其特征在于：步骤（2）中所述的表面活性剂为聚乙二醇月桂酸酯、椰油基羟乙基磺酸钠、十二醇聚氧乙烯醚硫酸钠中的一种或多种。
4.根据权利要求1所述的一种陶瓷微珠研磨介质的制备方法，其特征在于：步骤（2）中所述的分散剂为聚乙烯吡咯烷酮、磷酸酯、聚乙烯醇中的一种或多种。
5.根据权利要求1所述的一种陶瓷微珠研磨介质的制备方法，其特征在于：步骤（3）中所述的鸡蛋蛋清的质量为浆料质量2～4%，蔗糖质量为浆料质量1～3%。
6.根据权利要求1所述的一种陶瓷微珠研磨介质的制备方法，其特征在于：步骤（4）中所述的烧制时间为40～50min。
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CN109824340A (zh) * 2019-02-28 2019-05-31 宁国慧宏耐磨材料有限公司 一种研磨介质的加工工艺
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CN112624729A (zh) * 2020-12-19 2021-04-09 安徽致磨新材料科技有限公司 一种金属与陶瓷复合研磨介质及其制备方法
CN112778021A (zh) * 2021-03-26 2021-05-11 浙江忠信新型建材股份有限公司 一种多孔的轻质抹灰石膏及其使用方法
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