CN107311678A - 一种长寿命铝熔体除气转子及其制作方法 - Google Patents

一种长寿命铝熔体除气转子及其制作方法 Download PDF

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CN107311678A
CN107311678A CN201710626651.5A CN201710626651A CN107311678A CN 107311678 A CN107311678 A CN 107311678A CN 201710626651 A CN201710626651 A CN 201710626651A CN 107311678 A CN107311678 A CN 107311678A
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宋振亚
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Abstract

本发明涉及一种长寿命铝熔体除气转子及其制作方法，其步骤是，首先利用碳化硅粉与工业级硅粉混合并加入粘接剂混炼后等静压成型制备保护套，在氮气气氛中烧结后得到15~20%的高显气孔率的陶瓷烧结体，对该保护套烧结体用氮化硼粉、氧化铝粉等物质进行进行浸渍填充处理，从而获得抗热震、抗高温氧化，耐铝液侵蚀的保护套；然后配制抗铝液侵蚀的高温粘结剂，并将保护套与常规石墨转子粘接组装，正常使用时，铝液面在保护套位置上下波动。这种增加了陶瓷保护套的转子使用寿命为常规石墨转子的三倍以上。

Description

一种长寿命铝熔体除气转子及其制作方法
技术领域
本发明涉及一种长寿命铝熔体除气用转子以及制作方法，除气转子用来对浇铸前熔化的铝液熔体进行除气，防止铝铸件中气孔的产生。
背景技术
铝及铝合金在熔炼过程中由于空气中水分的进入、铝锭表面油污等有机物的带入等原因，铝熔体中不可避免存在氢元素，在后续的浇铸冷却过程中，氢元素在铝中的溶解度迅速降低，并以氢气泡的形式从铝中析出，形成气孔，严重影响产品质量。因此，在熔炼完成后，浇铸之前，需要对铝熔体进行除气（除氢）处理。传统技术使用固体除气剂，因产生大量烟雾，生产环境恶劣，逐渐被淘汰，取而代之的是使用惰性气体旋转吹喷的技术进行铝熔体除气处理。该技术的核心部件为一端带有旋转喷头的中空转杆，即转子，使用时插入铝或铝合金熔体中，惰性气体通过其中间孔道吹入，沿着转子底端的旋转喷头喷出，形成的气泡由于喷头高速旋转被打散成大量的小气泡，铝熔体中的氢将依附在这些小气泡上析出成氢气，同时吸附铝熔体中的杂质颗粒一起上浮至液面，从而达到除气（除氢）净化之目的。
制作铝熔体除气转子的材料，需要具有耐高温、耐氧化、耐铝液侵蚀、可机加工、耐热冲击，且具有一定的机械强度等性能，一般情况下，一种材料很难同时满足上述性能。目前技术水平下，铝熔体除气转子大多采用石墨材料制作，因为石墨材料的抗热冲击性能优秀，可机加工，且铝液对石墨不浸润，但不耐高温氧化是石墨材料的致命弱点。大量使用实践表明：石墨转子工作时，浸入铝液面之下的部分不与氧气接触，几乎不发生氧化反应，只有铝液冲刷，材料损耗小；在铝液面之上的部分，虽然与氧气接触，发生氧化烧蚀，但没有铝液冲刷，烧蚀速度并不高；而石墨转子与铝液液面接触的位置，由于温度高，并存在一定量的氧气，导致石墨氧化严重，且同时石墨转子转动时铝液对转子表面高速冲刷，导致石墨转子液面位置迅速变细而折断报废。一般正常使用的石墨转子寿命为14~20天，更换石墨转子不仅增加劳动作业强度，有时需要中断生产节奏，而且增加了生产成本，因此需要提高转子的使用寿命。
已知的碳化硅、氮化硅及塞隆陶瓷具有优良的抗铝液侵蚀能力及抗高温氧化能力。
发明内容
为了克服上述现有技术的不足，本发明提供了一种长寿命铝熔体除气用转子，通过给石墨转子嵌套上抗铝液冲刷侵蚀，且耐高温氧化、耐热冲击的保护套管，以提高其在铝液中使用寿命。
本发明的技术方案是，一种长寿命铝熔体除气转子，其包括中空的石墨转杆1，在石墨转杆的下端设有旋转喷头4，其特征是，在石墨转杆上位于铝液面位置嵌套有抗热震抗铝液侵蚀的碳化硅陶瓷保护套2，石墨转杆与保护套之间用抗铝液侵蚀的粘接剂3粘接。
所述的长寿命铝熔体除气转子，包括以下制作步骤：
一、制备碳化硅陶瓷保护套
1）用碳化硅粉体与硅粉加入成型助剂混炼后，通过冷等静压的成型方式制备保护套生坯，在100~120℃下烘干180~240分钟，对烘干后的保护套干坯内壁粗化处理；
2）将保护套的生坯烘干后在氮气气氛下烧结；烧结温度为1300℃~1400℃，烧结时间为300~360分钟；烧结后的保护套显气孔率为15%~20%；
二、保护套浸渍处理
将烧结好的保护套在浸渍液中浸渍处理3~5次；浸渍剂配置方法为在磷酸二氢铝溶液中加入重量比为15~20%的煅烧氧化铝粉及5~6%的氮化硼粉均匀混合；浸渍时间15~20分钟，取出后在100~120℃烘干30~40分钟；
三、配制粘接剂
粘接剂由重量比为5~10%的石墨粉、50~60%的氧化铝粉、20~30%的氧化镁粉，15~25%的磷酸二氢铝溶液充分混炼制得；
四、按照实际需要加工石墨搅拌杆，并对外表面液面位置上下10厘米的区域进行粗化处理。
五、将第三步骤制得的粘接剂涂覆于第二步骤制得的保护套内表面及第四步加工好的石墨杆的外表面粗化区域后，将两者粘接组装在一起，并置于100℃~120℃下烘干40~60分钟，得到长寿命铝熔体除气转子。
上述步骤一所述的保护套管烧结后的显气孔率控制在20%~25%，较大的气孔率可以容纳材料受热膨胀变形，减小热应力值，且在热应力导致的裂纹尖端碰到气孔可以发生钝化或偏转，从而在宏观上保证了保护套的热震抗力；另一方面，所选陶瓷材料具有较高的导热率，壁厚控制在6mm以下，进一步降低了温度剧烈变化时产生的热应力，确保保护套不炸裂。但气孔率不可太高防止铝液或铝渣穿过保护套的气孔对石墨杆造成腐蚀。保护管的长度保证铝液液面波动在其范围内即可。
上述步骤二的浸渍处理，可以在保护套的细孔中填入耐高温的材料，起到封孔的作用，防止铝液或铝渣透过保护套腐蚀石墨杆。在浸渍剂中加入氮化硼可以起到如下作用：氮化硼由于具有表面惰性，可以减少铝液、铝渣在保护套表面的粘接；另一方面，浸渍剂固化后，氮化硼除了可以阻挡铝液渗入外还可利用自身可变形的特性钝化热裂纹的尖端，提高孔隙填充物的热振抗力。
上述步骤三中，氧化镁微粉促进了磷酸二氢铝结合剂的固化，使得整体转子粘接后无需在高温下烘烤，避免石墨的氧化；少量的石墨存在可以保持粘结层的还原气氛，有效保护石墨杆不被氧化；氧化铝及氧化镁粉在高温下可发生尖晶石化，粘接层整体发生微膨胀，既增加保护套与内层石墨杆的粘接强度，又起到阻止铝液从粘接层渗入的作用。
与现有技术相比，本发明的有益效果是将除气转子使用寿命提高三倍以上。
附图说明
图1为长寿命铝熔体除气转子结构示意图。
具体实施方式
下面结合具体实施例对本发明进一步说明。
实施例1：包括如下步骤：
（1）用碳化硅粉与工业级硅粉按照85:15混合，加入5%的聚乙烯醇胶水混炼后，在150MPa压力下冷等静压成型制备保护套生坯，在100℃下烘干180分钟，对烘干后的保护套干坯内壁粗化处理。所述碳化硅粉体的中位粒径（d50）为250微米；所述的工业级硅粉的中位粒径（d50）为10微米，硅含量为98%以上；所述的保护套生坯的壁厚为4毫米，长度为200毫米，内径为80毫米。
（2）将保护套的生坯烘干后在氮气气氛下加热至1350℃进行氮化烧结，烧结时间为300分钟；烧结后的保护套显气孔率为15%。
（3）保护套浸渍处理
将烧结好的保护套在浸渍液中浸渍处理4次。浸渍剂配置方法为在磷酸二氢铝溶液中加入重量比为15%的中位粒径（d50）为2微米的煅烧氧化铝粉及5%的中位粒径（d50）为0.2微米的氮化硼粉均匀混合；浸渍时间15分钟，取出后在100℃烘干30分钟；所述磷酸二氢铝溶液的质量浓度为12%。
（4）配制粘接剂
粘接剂由重量比为5%的石墨粉、55%的氧化铝粉、20%的氧化镁粉，20%的磷酸二氢铝溶液充分混炼制得；所述的石墨粉碳含量大于99%，中位粒径5微米，所述的氧化铝粉为α相，中位粒径为（d50）为10微米，所述的氧化镁粉中位粒径为（d50）为2微米，所述磷酸二氢铝溶液的质量浓度为35%。
（5）按照实际需要加工外径为78毫米石墨搅拌杆，并对外表面液面位置上下10厘米的区域进行粗化处理。
（6）将第（4）步骤制得的粘接剂涂覆于第（2）步骤制得的保护套内表面及第（5）步加工好的石墨杆的外表面粗化区域后，将两者粘接组装在一起，并置于100℃℃下烘干40分钟，得到长寿命铝熔体除气转子。
实施例2：包括如下步骤：
（1）用碳化硅粉与硅粉按照9:1混合，加入5%的聚乙烯醇胶水混炼后，在120MPa压力下冷等静压的成型制备保护套生坯，在100℃下烘干180分钟，对烘干后的保护套干坯内壁粗化处理；所述碳化硅粉体的中位粒径（d50）为300微米，所述的硅粉的中位粒径（d50）为20微米；所述的保护套生坯的壁厚为6毫米，长度为300毫米内径为，80毫米。
（2）将保护套的生坯烘干后在氮气气氛下烧结；烧结温度为1400℃，烧结时间为360分钟；烧结后的保护套显气孔率为20%。
（3）保护套浸渍处理
将烧结好的保护套在浸渍液中浸渍处理5次；浸渍剂配置方法为在磷酸二氢铝溶液中加入重量比为20%的中位粒径（d50）为3微米的煅烧氧化铝粉及6%的中位粒径（d50）为0.5微米的氮化硼粉均匀混合；浸渍时间20分钟，取出后在120℃烘干40分钟；所述磷酸二氢铝溶液的质量浓度为15%。
（4）配制粘接剂
粘接剂由重量比为10%的石墨粉、50%的氧化铝粉、25%的氧化镁粉，15%的磷酸二氢铝溶液充分混炼制得；所述的石墨粉碳含量大于99%，中位粒径10微米，所述的氧化铝粉为α相，中位粒径为（d50）为20微米，所述的氧化镁粉中位粒径为（d50）为2.5微米，所述磷酸二氢铝溶液的质量浓度为40%。
（5）按照实际需要加工外径为78毫米石墨搅拌杆，并对外表面液面位置上下10厘米的区域进行粗化处理。
（6）将第（4）步骤制得的粘接剂涂覆于第（2）步骤制得的保护套内表面及第（5）步加工好的石墨杆的外表面粗化区域后，将两者粘接组装在一起，并置于120℃下烘干60分钟，得到长寿命铝熔体除气转子。
以上三个实施例产品用于铝液熔体除气使用寿命总结于下表：
序号 应用场合 使用寿命
实施例1 680℃铝液除气 75天
实施例2 650℃铝液除气 70天
常规石墨转子 650℃铝液除气 19天
如上表所示，增加保护套的转子寿命为常规产品的三倍以上。

Claims (6)

1.一种长寿命铝熔体除气转子，其包括中空的石墨转杆（1），在石墨转杆的下端设有旋转喷头（4），其特征是，在石墨转杆上位于铝液面位置嵌套有抗热震抗铝液侵蚀的碳化硅陶瓷保护套（2），石墨转杆与保护套之间用抗铝液侵蚀的粘接剂（3）粘接。
2.如权利要求1所述一种长寿命铝熔体除气转子，其特征在于包括以下制作步骤：
（1）用碳化硅及硅粉按照90:10~85:15的比例混合并加入5%的聚乙烯醇胶水后混炼，在120~150MPa的压力下冷等静压成型制备保护套生坯，将内壁粗化处理后置于100~120℃下烘干180~240分钟；
（2）将保护套的生坯烘干后在氮气或氩气保护气氛下烧结；烧结温度为1300℃~1400℃，烧结时间为300~360分钟；
（3）保护套浸渍处理
将烧结好的保护套在浸渍液中浸泡15~30分钟，取出后在100~120℃烘干30~40分钟，重复上述浸渍处理3~5次；
（4）配制粘接剂
粘接剂包括下述组分：5~10%的石墨粉，50~60%的氧化铝粉、20~30%的氧化镁粉，15~25%的磷酸二氢铝溶液；
（5）根据需要尺寸加工石墨转杆，对转杆表面工作时液面位置上下10厘米范围进行粗化处理；
（6）将第（4）步骤制得的粘接剂涂覆于第（3）步骤制得的保护套内表面及第（5）步骤得到的石墨杆表面粗化区域后，将两者粘接组装在一起，并置于100℃~120℃下烘干40~60分钟，得到长寿命铝熔体除气转子。
3.如权利要求2所述一种长寿命铝熔体除气转子，其特征是，制作步骤（1）中所述制作保护套的碳化硅粉中位粒径（d50）为250~300微米；工业级硅粉的中位粒径（d50）为10~20微米；生坯的壁厚为3~6毫米，长度为200~300毫米；按制作步骤（2）烧结后的保护套显气孔率为15%~20%。
4.如权利要求2所述一种长寿命铝熔体除气转子，其特征是，制作步骤（3）所述的浸渍液为磷酸二氢铝溶液中加入重量比为15~20%的粒径为2~3微米的煅烧氧化铝粉及5~6%的粒径为0.2~0.5微米的氮化硼粉均匀混合制成；所述磷酸二氢铝溶液的浓度为10%~15%（wt%）。
5.如权利要求2所述一种长寿命铝熔体除气转子，其特征是，制作步骤（4）所述粘接剂的石墨粉碳含量大于99%，粒径为8~10微米；所述的氧化铝粉为α相，中位粒径（d50）为10~20微米；所述的氧化镁粉中位粒径为（d50）为2~2.5微米，所述的磷酸二氢铝溶液的浓度为35~40%。
6.如权利要求2所述一种长寿命铝熔体除气转子，其特征是，制作步骤（5）所述石墨转杆的外径比保护套的内径小2~5毫米；石墨杆外表面铝液面区域粗化处理手段包括粗砂纸打磨和车削螺纹。
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