CN107857560B - 铝液低压铸造用高强度陶瓷保温杯制备工艺 - Google Patents
铝液低压铸造用高强度陶瓷保温杯制备工艺 Download PDFInfo
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Abstract
本发明公开了一种铝液低压铸造用高强度陶瓷保温杯制备工艺，采用挤出成型工艺，具体步骤包括配料、搅拌捏合、陈腐、练泥挤出成型、干燥、烧结、机加工和涂料等步骤。本发明的保温杯制备工艺具有生产成本低、参数易控制、生产效率高等特点，通过本发明制备的陶瓷保温杯具有比重轻、保温性好、强度高等优点。
Description
技术领域
本发明涉及冶金行业中的铸造陶瓷材料制备领域，具体地说，是铝液低压铸造用高强度陶瓷保温杯制备工艺。
背景技术
低压铸造是广泛用于汽车轮毂、纺织机械与航空航天工业等精密铝合金铸件生产的一种工艺，其主要用来铸造一些质量要求高的铝合金制品。保温杯是低压铸造系统中的重要部件，其作用是与升液管配合，将铝液通过压力引流至成型模具中。因此，保温杯在外观上要求具有较精确的尺寸，内质上要求具有良好的保温性能、好的耐高温和耐侵蚀性、良好的抗热震性及较高的产品强度，从而更好地满足低压铸造的工艺要求。现有低压铸造机上的保温杯常用硅酸铝纤维、不锈钢或其它金属合金，硅酸铝纤维材质虽然具有良好的保温性，但使用寿命短、强度低、表面易掉粉、耐冲刷性差；而不锈钢或金属合金材质的浇口套则保温性能不好、易粘铝，且易带入金属杂质。研究一种高强度、保温性好的陶瓷保温杯将大大提升现有铝液低压铸造工艺技术要求，且有助于解决减少保温杯使用过程中由于强度差造成漏铝、脱模困难，以及经常更换保温杯带来的人工成本高、对铸造设备损害大等问题。
发明内容
本发明的目的在于提供一种铝液低压铸造用高强度陶瓷保温杯制备工艺，该工艺具有生产成本低、参数易控制、生产效率高等特点，通过本发明制备的陶瓷保温杯具有比重轻、保温性好、强度高等优点。
为了实现上述目的，本发明采取以下技术方案予以实现，一种铝液低压铸造用高强度陶瓷保温杯制备工艺，采用挤出成型工艺，具体包括如下步骤：
（1）配料：按重量百分比依次称量水洗高岭土 40%~60%；煅烧高岭土 15%~30%；陶瓷纤维棉 10%~20%；氧化铝粉 5%~10%；蒙脱石粉 2%~8%，另外加入粉料重量的20%~30%无机粘结剂；
（2）搅拌捏合：将上述称量好的粉料先倒入自动搅拌机内搅拌20~35min，再加入无机粘结剂，捏合粉料至可塑性泥料；
（3）陈腐：将泥料取出，至恒温恒湿条件下陈腐12~24h；
（4）练泥挤出成型：将陈腐好的泥料放入练泥机内反复练泥2~3次，再将练好的泥料放入挤出机内挤出成型；
（5）干燥：将上述挤出好坯体放在干燥车上，经自然风干，直至坯体具有一定表面强度，其中坯体含水率需低于10%；
（6）烧结：将干燥好坯体放入电炉或煤气炉烧结，烧结温度控制在600~800℃；
（7）机加工：将烧结好的产品根据客户尺寸和形状要求进行机加工，包括内外径车削和开槽等；
（8）涂料：将机加工完成的产品进行表面和内部涂料，最终获得保温杯成品。
作为本发明的进一步改进，所述步骤（1）中水洗高岭土、煅烧高岭土、氧化铝粉均采用325目及以上粒径，陶瓷纤维棉采用硅酸铝纤维棉、高铝纤维棉和含锆纤维棉中的一种或组合。
作为本发明的进一步改进，所述步骤（1）中无机粘结剂为磷酸二氢铝或硅溶胶的其中一种。
作为本发明的进一步改进，所述步骤（1）中添加珍珠岩粉，粒径为200目，加入量为1%~8%。
作为本发明的进一步改进，所述步骤（3）中恒温条件为20~25℃，恒湿为空气中相对湿度60%~80%。
作为本发明的进一步改进，所述步骤（5）中自然风干时间为24~48h。
作为本发明的进一步改进，所述步骤（6）中坯体烧成周期为12~18h。
作为本发明的进一步改进，所述步骤（8）中外表面涂料采用滑石粉和硅溶胶混合制得的涂料涂覆。
作为本发明的进一步改进，所述步骤（8）中内表面涂料采用氮化硼水性涂料涂覆。
本发明的铝液低压铸造用高强度陶瓷保温杯制备工艺，首先在配方上采用以高岭土为主要原料，从而使得泥料具有较强的可塑性，满足了后期挤出工艺的要求，另外加入煅烧高岭土和脊性料氧化铝达到减少泥料收缩、提升产品白度和增加产品强度的作用，加入硅酸铝纤维棉可以有效提升保温性能，同时由于纤维增韧作用，大大提高了产品的抗拉伸强度；适量加入珍珠岩粉可进一步提升产品保温性；同时配方上还采用磷酸二氢铝或硅溶胶为粘结剂，保证了坯体强度，和后期烧成的产品强度。
本发明另一个独特之处在于，采用600~800℃的低温烧结工艺，虽然在产品强度上会有所损失，但是对于后期坯体机加工和产品保温性具有重要作用。因为烧结温度越高，产品瓷化好、强度高、硬度高，导致机加工磨刀厉害且容易崩裂，不利于产品规模化生产；并且，陶瓷纤维棉在高温下（约1000℃）会出现纤维粉化，非但不能起到增韧强度作用，还会收缩急剧失去保温效果。因此，本发明克服了传统保温杯配料上采用硅酸铝棉和硅溶胶，成型上往往液压压制成型，其制备的保温杯强度低、成本高、使用寿命短等缺陷。本发明的保温杯在生产工艺上做出了重大改进，产品抗压强度达到15Mpa及以上，而普通硅酸铝纤维材质的保温杯强度只有约5MPa。产品经客户试用后，产品使用寿命上延迟了2倍以上。
具体实施方式
下面通过具体实施例来描述本发明。
实施例1：
（1）配料：按重量百分比依次称量水洗高岭土 40%；煅烧高岭土30%；陶瓷纤维棉15%；氧化铝粉 8%；膨润土 7%，另外加入粉料重量的25%的磷酸二氢铝溶液；
（2）搅拌：将上述称量好的粉料先倒入自动搅拌机内搅拌20min，再加入称量好的磷酸二氢铝溶液，搅拌均匀至可塑性泥料；
（3）陈腐：将泥料取出，至恒温恒湿（温度20~25℃，相对湿度60%~80%）条件下陈腐12h；
（4）练泥挤出成型：将陈腐好的泥料放入练泥机内反复练泥2~3次，再将练好的泥料放入挤出机内挤出成型；
（5）干燥：将上述挤出好坯体放在干燥车上，经自然风干48h，直至坯体具有一定表面强度，其中坯体含水率需低于10%；
（6）烧结：将干燥好坯体放入电炉或煤气炉烧结，烧结温度控制在800℃，烧成周期为16h；
（7）机加工：将烧结好的产品根据客户尺寸和形状要求进行机加工，包括内外径车削和开槽等；
（8）涂料：将机加工完成的产品进行表面和内部涂料，其中外表面涂覆滑石粉和硅溶胶涂料，内表面涂覆水性氮化硼涂料，最终获得保温杯成品。
实施例2：
（1）配料：按重量百分比依次称量水洗高岭土 60%；煅烧高岭土15%；陶瓷纤维棉10%；氧化铝粉 10%；膨润土 5%，另外加入粉料重量的20%的磷酸二氢铝溶液；
（2）搅拌：将上述称量好的粉料先倒入自动搅拌机内搅拌25min，再加入称量好的磷酸二氢铝溶液，搅拌均匀至可塑性泥料；
（3）陈腐：将泥料取出，至恒温恒湿（温度20~25℃，相对湿度60%~80%）条件下陈腐14h；
（4）练泥挤出成型：将陈腐好的泥料放入练泥机内反复练泥2~3次，再将练好的泥料放入挤出机内挤出成型；
（5）干燥：将上述挤出好坯体放在干燥车上，经自然风干36h，直至坯体具有一定表面强度，其中坯体含水率需低于10%；
（6）烧结：将干燥好坯体放入电炉或煤气炉烧结，烧结温度控制在800℃，烧成周期为18h；
（7）~（8）：同实施例1。
实施例3：
（1）配料：按重量百分比依次称量水洗高岭土 50%；煅烧高岭土20%；陶瓷纤维棉20%；氧化铝粉 5%；膨润土 5%，另外加入粉料重量的30%的硅溶胶溶液；
（2）搅拌：将上述称量好的粉料先倒入自动搅拌机内搅拌35min，再加入称量好的硅溶胶溶液，搅拌均匀至可塑性泥料；
（3）陈腐：将泥料取出，至恒温恒湿（温度20~25℃，相对湿度60%~80%）条件下陈腐24h；
（4）练泥挤出成型：将陈腐好的泥料放入练泥机内反复练泥2~3次，再将练好的泥料放入挤出机内挤出成型；
（5）干燥：将上述挤出好坯体放在干燥车上，经自然风干48h，直至坯体具有一定表面强度，其中坯体含水率需低于10%；
（6）烧结：将干燥好坯体放入电炉或煤气炉烧结，烧结温度控制在600℃，烧成周期为12h；
（7）~（8）：同实施例1。
实施例4：
（1）配料：按重量百分比依次称量水洗高岭土 45%；煅烧高岭土25%；陶瓷纤维棉20%；氧化铝粉 5%；膨润土 2%；珍珠岩粉 3%，另外加入粉料重量的25%的硅溶胶溶液；
（2）搅拌：将上述称量好的粉料先倒入自动搅拌机内搅拌20min，再加入称量好的硅溶胶溶液，搅拌均匀至可塑性泥料；
（3）陈腐：将泥料取出，至恒温恒湿（温度20~25℃，相对湿度60%~80%）条件下陈腐18h；
（4）练泥挤出成型：将陈腐好的泥料放入练泥机内反复练泥2~3次，再将练好的泥料放入挤出机内挤出成型；
（5）干燥：将上述挤出好坯体放在干燥车上，经自然风干36h，直至坯体具有一定表面强度，其中坯体含水率需低于10%；
（6）烧结：将干燥好坯体放入电炉或煤气炉烧结，烧结温度控制在650℃，烧成周期为14h；
（7）~（8）：同实施例1。
本发明可用其他的不违背本发明的精神和主要特征的具体形式来概述。因此，无论从哪一点来看，本发明的上述实施方案只能认为是对本发明的说明而不能限制本发明，因此，在与本发明的权利要求书相当的含义和范围内的任何变化，都应认为是包括在权利要求书的范围内。
Claims (9)
1.一种铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，采用挤出成型工艺，具体包括以下步骤：
（1）配料：按重量百分比依次称量水洗高岭土 40%~60%；煅烧高岭土 15%~30%；陶瓷纤维棉 10%~20%；氧化铝粉 5%~10%；蒙脱石粉 2%~8%，另外加入粉料重量的20%~30%无机粘结剂；
（2）搅拌捏合：将上述称量好的粉料先倒入自动搅拌机内搅拌20~35min，再加入无机粘结剂，捏合粉料至可塑性泥料；
（3）陈腐：将泥料取出，至恒温恒湿条件下陈腐12~24h；
（4）练泥挤出成型：将陈腐好的泥料放入练泥机内反复练泥2~3次，再将练好的泥料放入挤出机内挤出成型；
（5）干燥：将上述挤出好坯体放在干燥车上，经自然风干，直至坯体具有一定表面强度，其中坯体含水率需低于10%；
（6）烧结：将干燥好坯体放入电炉或煤气炉烧结，烧结温度控制在600~800℃；
（7）机加工：将烧结好的产品根据客户尺寸和形状要求进行机加工，包括内外径车削和开槽；
（8）涂料：将机加工完成的产品进行表面和内部涂料，最终获得保温杯成品。
2.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（1）中水洗高岭土、煅烧高岭土、氧化铝粉均采用325目及以上粒径，陶瓷纤维棉采用硅酸铝纤维棉、高铝纤维棉和含锆纤维棉中的一种或组合。
3.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（1）中无机粘结剂为磷酸二氢铝或硅溶胶的其中一种。
4.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（1）中添加珍珠岩粉，粒径为200目，加入量为1%~8%。
5.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（3）中恒温条件为20~25℃，恒湿为空气中相对湿度60%~80%。
6.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（5）中自然风干时间为24~48h。
7.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（6）中坯体烧成周期为12~18h。
8.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（8）中外表面涂料采用滑石粉和硅溶胶混合制得的涂料涂覆。
9.根据权利要求1所述的铝液低压铸造用高强度陶瓷保温杯制备工艺，其特征在于，所述步骤（8）中内表面涂料采用氮化硼水性涂料涂覆。
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| CN103480826A (zh) * | 2012-12-20 | 2014-01-01 | 江苏凯特汽车部件有限公司 | 一种新型低压铸造铝合金车轮用陶瓷保温杯 |
| CN103613359A (zh) * | 2013-12-13 | 2014-03-05 | 杭州中亚新材料科技有限公司 | 一种铝及铝合金铸造用的无机高温粘结剂 |
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| CN103342548A (zh) * | 2013-07-17 | 2013-10-09 | 邓慕斯 | 一种电陶炉保温层及其制备方法 |
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