CN107500790B - 一种高温防脱碳涂料及其制备方法 - Google Patents
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Abstract
一种高温防脱碳涂料,属于耐火材料技术领域,所述涂料由A、B两种组分组成,所述A、B两种组分所占的重量百分含量分别为60~70%和30~40%;所述A组分的重量百分比组成为:高铝矾土粉26~33%,石墨15~25%,碳化硅15~35%,锆刚玉粉3~7%,Al2O3超微粉13~17%和硅铝胶4~7%;所述B组分的重量百分比组成为:悬浮剂20~30%,粘结剂70~80%。本发明解决轧钢过程中钢材脱碳问题的高温防脱碳涂料使用后在钢材表面形成一个保护膜,降低脱碳层深度,大大提高产品成材率以及钢材表面硬度及使用性能,增加金属回收率,降低生产成本,提高经济效益。
Description
技术领域
本发明属于耐火材料技术领域,特别是涉及一种解决碳钢、中碳钢、高碳钢等轧钢过程中脱碳问题的高温防脱碳涂料及其制备方法。
背景技术
在长期生产过程中,由于钢材在轧前加热过程中,同时在轧后的冷却过程中存在严重脱碳,使钢材的疲劳强度显著降低,容易产生裂纹引起疲劳断裂。
根据轧钢生产情况,解决轧钢过程中容易脱碳的钢种有以下几种:
1、轴承钢;
2、高碳工具钢;
3、弹簧钢;
4、帘线钢等。
目前,世界各国对于轧钢过程中钢材脱碳问题一直没有行之有效的解决办法,通常采用用砂轮研磨或深入酸洗的办法去掉脱碳层这一方法,这种方法的明显缺点为:增加过程工艺成本和金属消耗,大大降低了产品成材率等。
针对目前解决轧钢过程中钢材脱碳问题的方法存在的缺陷,本申请人经过长期研究,成功研制出一种能够彻底解决轧钢过程中钢材脱碳问题的高温防脱碳涂料。
发明内容
本发明的发明目的是提供一种高温防脱碳涂料及其制备方法与施工工艺,要解决的技术问题是:针对目前解决轧钢过程中钢材脱碳问题的方法存在的缺陷,本发明提供一种能够彻底解决轧钢过程中钢材脱碳问题的高温防脱碳涂料。本发明防脱碳涂料具有较强的抗氧化性、耐湿热,良好的热震稳定性、隔热保温性、电绝缘性、附着性等优点;使用本发明的高温防脱碳涂料在使用的钢材上形成多层防护膜,有效降低钢坯高温脱碳层深度,大大提高产品成材率以及钢材表面硬度及使用性能,降低生产成本,提高经济效益。
为了解决上述问题,本发明采取的技术方案为:
一种高温防脱碳涂料,所述涂料由A、B两种组分组成,所述A、B两种组分所占的重量百分含量分别为60~70%和30~40%;所述A组分的重量百分比组成为:高铝矾土粉26~33%,石墨15~25%,碳化硅15~35%,锆刚玉粉3~7%,Al2O3超微粉13~17%和硅铝胶4~7%;所述B组分的重量百分比组成为:悬浮剂20~30%,粘结剂70~80%。
所述粘结剂为酚醛树脂。
所述高铝矾土粉的粒度为-300目;高铝矾土粉中Al2O3的质量百分含量≥80%,Fe2O3的质量百分含量≤2%;高铝矾土粉的体积密度≥2.9g/cm3。
所述石墨的粒度为-300目,固定碳含量≥98%,耐火度>2500℃。
所述碳化硅的粒度为-300目,碳化硅中SiC的质量百分含量≥98%,碳化硅的耐火度>1830℃。
所述锆刚玉的粒度为-180目,锆刚玉中,ZrO2的含量38~44%,Al2O3的含量50~60%,SiO2的含量≤0.5%,Fe2O3的质量百分含量≤0.2%。
所述Al2O3超微粉的原晶粒度为0.3~0.5μm,Al2O3超微粉中,Al2O3的含量≥99.7%,Na2O的含量≤0.1%,SiO2的含量≤0.05%,Fe2O3的质量百分含量≤0.03%,真比重3.95g/cm3。
所述硅铝胶粒径为1~3mm,SiO2的含量≥75%,Al2O3的含量≥25%,Na2O的含量≤0.1%,Fe2O3的质量百分含量≤0.02%。
所述的高温防脱碳涂料的制备方法,将各原料按比例混合,直接混合后包装即得。
本发明产品解决轧钢过程中钢材脱碳问题的高温防脱碳涂料的施工方法:
1)根据轧钢钢材的生产情况,选定需要施工的部位;
2)将本发明产品搅拌均匀,以压缩空气或氮气作为动力,使用专用喷枪、喷射泵泵抽气送将产品形成雾状,均匀地喷补在作业部位;
3)施工完毕即可立即进入加热炉进行生产。
与现有技术相比,本发明具有以下优点:
本发明解决轧钢过程中钢材脱碳问题的高温防脱碳涂料使用后在钢材表面形成一个保护膜,降低脱碳层深度,大大提高产品成材率以及钢材表面硬度及使用性能,增加金属回收率,降低生产成本,提高经济效益(本发明产品的性能指标详见表1)。
表1本发明高温防脱碳涂料的理化指标
2、本发明产品解决轧钢过程中钢材脱碳问题的高温防脱碳涂料防粘渣性能优良,在作业状态下呈胶体状,不收缩、无裂纹,具有较强的抗氧化性、耐湿热、良好的热震稳定性等优点。
3、本发明产品解决轧钢过程中钢材脱碳问题的高温防脱碳涂料使用范围广泛,几乎在所有的轧钢行业均可用到,且使用效果明显。
4、在使用本发明的高温防脱碳涂料过程中,有毒气体、粉尘逸出量为零,无噪声产生,作业方便,可减少环境污染,有利于环境保护,其社会效益显著。
具体实施方式
以下结合具体实施例,对本发明进一步说明。以下实施例仅用于说明本发明而非用于限制本发明的范围。
本发明中诸如“-300目”代表的含义是小于等于300目。
实施例1
一种高温防脱碳涂料,与实施例1不同之处在于:所述涂料由A、B两种组分组成,所述A、B两种组分所占的重量百分含量分别为60%和40%;所述A组分的重量百分比组成为:高铝矾土粉33%,石墨25%,碳化硅15%,锆刚玉粉3%,Al2O3超微粉17%和硅铝胶7%;所述B组分的重量百分比组成为:悬浮剂20%,粘结剂80%。其余同实施例1。
所述粘结剂为酚醛树脂。
所述高铝矾土粉的粒度为-300目;所述高铝矾土粉中,Al2O3的质量百分含量≥80%,Fe2O3的质量百分含量≤2%,高铝矾土粉的体积密度≥2.9g/cm3。
所述石墨采用的是青岛天和达石墨有限公司所产的型号为:T890石墨,石墨的粒度为-300目,固定碳含量≥98%,耐火度>2500℃。
所述碳化硅采用兰州产石油焦碳化硅,所述碳化硅的粒度为-300目,碳化硅中,SiC的质量百分含量≥98%,耐火度>1830℃。
所述锆刚玉的粒度为-180目,所述锆刚玉采用的是河南锐石再生资源集团股份有限公司所生产的高锆刚玉,型号为ZA40,所述锆刚玉中ZrO2的含量38~44%,Al2O3的含量50~60%,SiO2的含量≤0.5%,Fe2O3的质量百分含量≤0.2%。
所述Al2O3超微粉采用的是河南济源兄弟材料有限公司所生产的Al2O3超微粉,型号是NX-1,所述Al2O3超微粉的原晶粒度为0.3~0.5μm,所述Al2O3超微粉中Al2O3的含量≥99.7%,Na2O的含量≤0.1%,SiO2的含量≤0.05%,Fe2O3的质量百分含量≤0.03%,真比重3.95g/cm3。
所述硅铝胶采用的是滨海市翰林催化材料有限公司所产硅铝胶-75,粒径为1~3mm,SiO2的含量≥75%,Al2O3的含量≥25%,Na2O的含量≤0.1%,Fe2O3的质量百分含量≤0.02%。
本发明解决轧钢过程中钢材脱碳问题的高温防脱碳涂料的制备方法:将各原料按比例直接混合后包装即可。
本发明产品解决轧钢过程中钢材脱碳问题的高温防脱碳涂料的施工方法:1)根据轧钢钢材的生产情况,选定需要施工的部位;2)将本发明产品搅拌均匀,以压缩空气或氮气作为动力,使用专用喷枪、喷射泵泵抽气送将产品形成雾状,均匀地喷补在作业部位;3)施工完毕即可立即进入加热炉进行生产。
实施例2
一种高温防脱碳涂料,与实施例1不同之处在于:所述涂料由A、B两种组分组成,所述A、B两种组分所占的重量百分含量分别为70%和30%;所述A组分的重量百分比组成为:高铝矾土粉26%,石墨15%,碳化硅35%,锆刚玉粉7%,Al2O3超微粉13%和硅铝胶4%;所述B组分的重量百分比组成为:悬浮剂30%,粘结剂70%。其余同实施例1。
实施例3
一种高温防脱碳涂料,与实施例1不同之处在于:所述涂料由A、B两种组分组成,所述A、B两种组分所占的重量百分含量分别为50%和50%;所述A组分的重量百分比组成为:高铝矾土粉30%,石墨20%,碳化硅25%,锆刚玉粉5%,Al2O3超微粉15%和硅铝胶5%;所述B组分的重量百分比组成为:悬浮剂25%,粘结剂75%。其余同实施例1。
将本发明高温防脱碳涂料应用时,发现其具有较强的抗氧化性、抗湿热性、良好的热震稳定性等优点;使用本发明高温防脱碳涂料后在钢材表面上形成一个保护膜,降低脱碳层深度,大大提高产品成材率以及钢材表面硬度及使用性能,增加金属回收率,降低生产成本,提高经济效益。
Claims (2)
1.一种高温防脱碳涂料,其特征在于,所述涂料由A、B两种组分组成,所述A、B两种组分所占的重量百分含量分别为60~70%和30~40%;所述 A 组分的重量百分比组成为:高铝矾土粉26~33%,石墨15~25%,碳化硅15~35%,锆刚玉粉3~7%,Al2O3超微粉13~17%和硅铝胶4~7%;所述B组分的重量百分比组成为:悬浮剂20~30%,粘结剂70~80%;其中,所述粘结剂为酚醛树脂;所述高铝矾土粉的粒度为-300目;高铝矾土粉中 Al2O3的质量百分含量≥80%,Fe2O3 的质量百分含量≤2%;高铝矾土粉的体积密度≥2.9g/cm3;所述石墨的粒度为-300目,固定碳含量≥98%,耐火度>2500℃;所述碳化硅的粒度为-300目,碳化硅中SiC的质量百分含量≥98%,碳化硅的耐火度>1830℃;所述锆刚玉的粒度为-180目,锆刚玉中,ZrO2的含量38~44%,Al2O3的含量50~60%,SiO2的含量≤0.5%,Fe2O3 的质量百分含量≤0.2%;所述Al2O3超微粉的原晶粒度为0.3~0.5μm,Al2O3超微粉中,Al2O3的含量≥99.7%,Na2O的含量≤0.1%,SiO2的含量≤0.05%,Fe2O3 的质量百分含量≤0.03%,真比重3.95g/cm3;所述硅铝胶粒径为1~3mm,SiO2的含量≥75%,Al2O3的含量≥25%,Na2O的含量≤0.1%,Fe2O3 的质量百分含量≤0.02%。
2.权利要求1所述的高温防脱碳涂料的制备方法,其特征在于,将各原料按比例混合,直接混合后包装即得。
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