CN108017409B - Low-temperature sintered silicon carbide honeycomb ceramic material and preparation method thereof - Google Patents
Low-temperature sintered silicon carbide honeycomb ceramic material and preparation method thereof Download PDFInfo
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Abstract
A low-temperature sintered silicon carbide honeycomb ceramic material and a preparation method thereof are disclosed, wherein the method comprises the following steps: weighing the required components according to the amount, and mixing the pore-forming agent and water into paste by stirring; stirring and mixing silicon carbide powder, ceramic composite material powder and paste, adding a lubricant, a dispersant and an extrusion aid, and stirring to form pug; extruding and molding the pug, and drying to obtain a silicon carbide honeycomb ceramic blank; sequentially carrying out dislocation plugging on the silicon carbide honeycomb ceramic to form a silicon carbide honeycomb ceramic plugging blank; and charging the silicon carbide honeycomb ceramic hole plugging blank into a furnace, heating the temperature to 900-1500 ℃ from room temperature, stopping heating, and cooling the blank to room temperature along with the furnace to prepare the required silicon carbide honeycomb ceramic material. The method has the advantages of low sintering temperature, reduced requirements on sintering equipment, energy conservation, reduced consumption and environmental protection; the prepared silicon carbide honeycomb ceramic material has the advantages of low thermal expansion coefficient, high mechanical strength and the like.
Description
Technical Field
The invention relates to a ceramic material and a manufacturing method thereof, in particular to a silicon carbide honeycomb ceramic material and a manufacturing method thereof.
Background
With the rapid development of the automobile industry, the pollution problem of automobile exhaust to the environment is increasingly prominent, and PM in the living environment seriously threatens human health. The diesel vehicle particulate filter DPF is an internationally recognized and effective diesel vehicle exhaust gas treatment technology and is one of the most practical diesel engine exhaust particulate treatment technologies internationally at present. The current particle traps have three main types: cordierite, silicon carbide and aluminum titanate, but most of the cordierite and the silicon carbide are currently used.
In recent years, silicon carbide materials have been rapidly developed as a novel diesel vehicle exhaust particulate filter material due to excellent heat resistance, corrosion resistance, low thermal expansion coefficient and high thermal conductivity, and the silicon carbide materials have the advantages of high porosity and strong thermal diffusion capacity, so that the temperature field in the filter can be uniformly distributed, and the regeneration effect and the stability effect of the silicon carbide particle catcher in the regeneration process are better than those of cordierite materials when the same carbon deposition amount is regenerated. In addition, the soot loading of the silicon carbide particle trap is much better than cordierite (silicon carbide carbon-like loading is about 10-12g/L, cordierite is about 4-6 g/L). Therefore, silicon carbide honeycomb ceramic materials are receiving more and more attention and are being used in a great amount in the evolution process of automobile exhaust.
Japanese Ibiden corporation first developed wall flow recrystallized silicon carbide (RSiC) in 1993, and produced RSiC-DPF in 2000 to be put into market as an exhaust gas filter material and a catalyst carrier. The RSiC material is prepared by sintering SiC at 2200 ℃ and under the protection of inert gases such as helium and the like through the processes of evaporation, recrystallization and the like. In 2000, the company NGK in Japan developed silicon-bonded silicon carbide (Si-SiC) in which silicon is filled in the middle of SiC grains, which are protected with an inert gas at about 1800 ℃ and sintered. The two silicon carbide ceramic materials have good performance in tail gas treatment due to good service performance, but the silicon carbide ceramic materials have complex production process, high sintering temperature, complex control, strict requirements on production equipment and high energy consumption, so the product price is high and the application of the carrier is limited.
Disclosure of Invention
In order to solve the defects in the prior art, the invention provides a low-temperature sintered silicon carbide honeycomb ceramic material and a preparation method thereof, and the silicon carbide honeycomb ceramic material with a honeycomb structure, a low thermal expansion coefficient, high mechanical strength and proper porosity and pore size distribution can be prepared at a lower temperature.
In order to achieve the purpose, the silicon carbide honeycomb ceramic material provided by the invention comprises silicon carbide powder, a ceramic composite material, a pore-forming agent, a lubricant, a dispersing agent, an extrusion auxiliary agent and water;
wherein the ceramic composite powder further comprises: titanium oxide, metallic aluminum, and boron-containing compounds.
Further, by mass, 100 parts of silicon carbide powder, 4-50 parts of ceramic composite material powder, 10-35 parts of pore-forming agent, 1-5 parts of lubricant, 0.2-1 part of dispersant, 0.2-1 part of extrusion aid and 23-40 parts of water.
Further, the silicon carbide powder is composed of two or more different silicon carbide powders with the granularity difference of more than 200 meshes, wherein the silicon carbide powder contains more than 99.0 percent by weight.
Further, the ceramic composite material powder comprises, by mass, 1-15 parts of the titanium oxide, 1-20 parts of the boron-containing compound and 1-15 parts of the metal aluminum powder.
Further, the boron-containing compound is one or more of borax, sodium borate, boron carbide, titanium boride, boric acid, potassium borate and boron oxide.
Further, the pore-forming agent is one or more of flour, graphite, potato flour, starch, cellulose, paraffin and PMMA, wherein the cellulose is one or two of carboxymethyl cellulose and hydroxymethyl cellulose.
Further, the lubricant is one or more of lubricating oil, engine oil, linseed oil and rapeseed oil.
Further, the dispersant refers to one or more of oleic acid and potassium laurate in the amphiphilic compound.
Further, the extrusion auxiliary agent is one or more of oleic acid, potassium laurate soap, glycerol and polyethylene glycol.
In order to achieve the aim, the preparation method of the silicon carbide honeycomb ceramic material provided by the invention comprises the following steps:
the preparation method of the low-temperature sintered silicon carbide honeycomb ceramic material comprises the following steps:
1) weighing the required components according to the amount, and mixing the pore-forming agent and water into paste by stirring;
2) stirring and mixing silicon carbide powder, ceramic composite material powder and paste, adding a lubricant, a dispersant and an extrusion aid, and stirring to form pug;
3) extruding and molding the pug, and drying to obtain a silicon carbide honeycomb ceramic blank;
4) sequentially carrying out dislocation plugging on the silicon carbide honeycomb ceramic to form a silicon carbide honeycomb ceramic plugging blank;
5) and charging the silicon carbide honeycomb ceramic hole plugging blank into a furnace, heating the temperature to 900-1500 ℃ from room temperature, stopping heating, and cooling the blank to room temperature along with the furnace to prepare the required silicon carbide honeycomb ceramic material.
Further, the step 5) further comprises the following steps: charging the silicon carbide honeycomb ceramic blank with the plugged holes into a furnace; raising the temperature from room temperature to 100-200 ℃ at a speed of less than 3 ℃/min; heating to 500-700 ℃ at a speed of less than 2.5 ℃/min, and preserving heat for 1-5 h; heating to 850-1000 ℃ at the speed of less than 2 ℃/min, and keeping the temperature for 1-5 h; heating to 900-1500 ℃ at the speed of less than 3 ℃/min, stopping heating, and cooling to room temperature along with the furnace to prepare the required silicon carbide honeycomb ceramic material.
Further, the step 5) further comprises the following steps: : heating from room temperature to 200 ℃ at a heating rate of 2.2 ℃/min; raising the temperature to 650 ℃ at the heating rate of 1.87 ℃/min, and keeping the temperature for 2 h; heating to 950 ℃ at the speed of 1.67 ℃/min, and keeping the temperature for 2 h; heating to 1100 deg.C at 1.67 deg.C/min, and maintaining for 4 hr; stopping heating, and cooling to room temperature along with the furnace to prepare the required silicon carbide honeycomb ceramic material.
Detailed tests are carried out on the silicon carbide honeycomb ceramic material provided by the invention, and the test results show that:
(1) the thermal expansion coefficient of the sintered silicon carbide honeycomb ceramic material at room temperature to 800 ℃ is as follows: 3.5-4.9 multiplied by 10 < -6 > -1;
(2) the pore diameter of the sintered silicon carbide honeycomb ceramic material is measured, more than 80 percent of micropores have the diameter of 5-32um, the median pore diameter of 10-20um and the pore volume of 0.3-0.35 cc/g; the micropore porosity of the sintered silicon carbide honeycomb ceramic material is 43-55%;
(3) the wall thickness of the sintered silicon carbide honeycomb ceramic material is 0.10-0.55mm, the number of holes per square centimeter of the silicon carbide honeycomb ceramic material is 3.8-62, the mechanical strength is that the axial direction is more than or equal to 8MPa, the transverse direction is more than or equal to 1.5MPa, and the 45-degree direction is more than or equal to 0.3 MPa;
the silicon carbide honeycomb ceramic material has the advantages of low sintering temperature, economic cost, simple process and the like, well reduces the requirement on sintering equipment, greatly saves energy, reduces consumption, is environment-friendly and favorable, and simultaneously the silicon carbide particle catcher has ideal catching effect and regeneration effect in the using process and has huge economic benefit and application prospect.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
FIG. 1 is a flow chart of a method for preparing a low temperature sintered silicon carbide honeycomb ceramic material according to the present invention;
FIG. 2 is a graph showing the thermal expansion of a silicon carbide honeycomb ceramic material according to the present invention from room temperature to 800 ℃;
FIG. 3 is an XRD pattern of a silicon carbide honeycomb ceramic material according to the present invention;
Detailed Description
The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, and it will be understood that they are described herein for the purpose of illustration and explanation and not limitation.
In order to achieve the purpose, the silicon carbide honeycomb ceramic material provided by the invention comprises silicon carbide powder, a ceramic composite material, a pore-forming agent, a lubricant, a dispersing agent, an extrusion auxiliary agent and water;
the silicon carbide honeycomb ceramic material provided by the invention is prepared from the following raw materials in parts by mass: 100 parts of silicon carbide powder, 4-50 parts of ceramic composite material, 10-35 parts of pore-forming agent, 1-5 parts of lubricant, 0.2-1 part of dispersant, 0.2-1 part of extrusion aid and 23-40 parts of water.
The silicon carbide powder is composed of two or more than two different types of silicon carbide with the granularity difference of more than 200 meshes, wherein the silicon carbide content is more than 99.0 percent (mass percentage); the mixing mass ratio of the large-particle silicon carbide to the small-particle silicon carbide is 1:1 to 1: 9;
the ceramic composite material is composed of titanium oxide, metal aluminum powder, boron-containing compound and other powder materials, wherein the purity of the titanium oxide is more than or equal to 99 percent (mass percent), and the proportion of the titanium oxide is 1-15 parts by mass; the purity of the boron-containing compound is more than or equal to 99.5 percent (mass percent), and the proportion is 1 to 20 parts by mass; the purity of the metal aluminum powder is more than or equal to 99 percent (mass percentage), and the proportion is 1 to 15 parts by mass. The three powders react at a certain temperature to generate a compound of titanium and boron, the compound can sinter the silicon carbide powder without changing the excellent characteristics of the silicon carbide, and the sintered silicon carbide material has a low thermal expansion coefficient;
the boron-containing compound is one or more of borax, sodium borate, boron carbide, titanium boride, boric acid, potassium borate, boron oxide and the like;
the pore-forming agent is one or more of flour, graphite, potato powder, starch, cellulose, paraffin, PMMA (polymethyl methacrylate), wherein the flour is firstly kneaded at the temperature of 80-120 ℃ to form paste with certain plasticity, and then the paste is added into the ceramic powder, and in addition, the cellulose is mainly one or two of carboxymethyl cellulose and hydroxymethyl cellulose;
the lubricant is one or more of lubricating oil, engine oil, linseed oil, rapeseed oil and the like;
the dispersant is one or more of amphiphilic compounds such as oleic acid, potassium laurate and the like;
the extrusion auxiliary agent is one or more of oleic acid, potassium laurate soap, glycerol, polyethylene glycol and the like;
the water refers to more than one time of distilled water or deionized water with the resistivity larger than 15M omega;
table 1 shows the specific raw material types and the corresponding proportions of examples 1 to 30 (based on 100 parts of the main silicon carbide powder, the other raw materials account for the specific gravity of the total amount of the main raw materials):
TABLE 1 proportions of the specific raw materials of examples 1-30
Fig. 1 is a flow chart illustrating a method for preparing a low-temperature sintered silicon carbide honeycomb ceramic material according to the present invention, and the method for preparing a low-temperature sintered silicon carbide honeycomb ceramic material according to the present invention will be described in detail with reference to fig. 1.
First, step 101, weighing raw materials: weighing the components according to the proportion;
Preferably, the sintering process in step 107 is: 1. heating from room temperature to 200 ℃ at a heating rate of 2.2 ℃/min; 2. raising the temperature to 650 ℃ at the heating rate of 1.87 ℃/min, and keeping the temperature for 2 h; 3. heating to 950 ℃ at the speed of 1.67 ℃/min, and keeping the temperature for 2 h; 4. heating to 1100 deg.C at 1.67 deg.C/min, and maintaining for 4 hr; 5. stopping heating, and finally cooling along with the furnace. The performance parameters of the support at different sintering temperatures are shown in Table 2.
TABLE 2 sintering temperature vs. Carrier Performance Table
The silicon carbide honeycomb ceramic material prepared by the invention has a honeycomb porous sintered body, and the coefficient of thermal expansion is 3.5-4.9 × 10 when the temperature is between room temperature and 800 DEG C-6℃-1Preferably, the content of the organic silicon compound can reach 4.0-4.7 × 10-6℃-1(ii) a The silicon carbide honeycomb ceramic material has 3.8 to 62 holes per square centimeter, preferably 10.85 to 46.5 holes per square centimeter; the thickness of the hole wall is 0.10-0.55mm, preferably 0.30-45 mm.
Compared with the silicon carbide honeycomb ceramic material sintered at different temperatures, the sintering temperature is from 950 ℃ to 1400 ℃, and as can be seen from the table, the thermal expansion coefficient of the carrier is 4.81 × 10 when the sintering temperature is 950 ℃ when the temperature is from room temperature to 800 ℃ along with the increase of the sintering temperature-6℃-1Reduced to 3.61 × 10 at 1400 deg.C-6℃-1(ii) a The compressive strength of the carrier is increased from axial 10.1MPa, transverse 1.5MPa and 45-degree direction 0.35MPa at the sintering temperature of 950 ℃ to axial 28MPa, transverse 15MPa and 45-degree direction 2MPa at 1400 ℃; but the water absorption is reduced from 30.19 percent to 21.6 percent, and the porosity is reduced from 48.78 percent to 37.18 percent.
FIG. 2 is a graph showing that the silicon carbide honeycomb ceramic material according to the present invention is between room temperature and 800 deg.CAs shown in fig. 2, curves a-f are the thermal expansion coefficients from room temperature to 800 c, corresponding to a thermal expansion coefficient of 4.81 × 10-6℃-1；b:4.76×10-6℃-1；c:4.65×10-6℃-1；d:4.43×10-6℃-1；e:4.03×10-6℃-1；f:3.61×10-6℃-1(ii) a The curve a-f corresponds to the sintering temperature of a:950 ℃; b is 1000 ℃; c, 1100 ℃; d is 1200 ℃; e, 1300 ℃; f, 1400 ℃.
FIG. 3 is an XRD spectrum of the silicon carbide honeycomb ceramic material according to the present invention, as shown in FIG. 3, the main peak of silicon carbide appears when 2 θ is about 36 ° and the peak intensity is very large, which indicates that the prepared material is mainly silicon carbide; the weak titanium diboride peak appears when the 2 theta is about 27 degrees, which shows that the ceramic composite material forms titanium diboride at a certain temperature, the compound can sinter silicon carbide powder without changing the excellent characteristics of the silicon carbide, and the sintered silicon carbide material has low thermal expansion coefficient.
Those of ordinary skill in the art will understand that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
1. The low-temperature sintered silicon carbide honeycomb ceramic material is characterized by comprising the following components in percentage by weight: 100 parts of silicon carbide powder, 4-50 parts of ceramic composite material powder, 10-35 parts of pore-forming agent, 1-5 parts of lubricant, 0.2-1 part of dispersant, 0.2-1 part of extrusion aid and 23-40 parts of water;
the silicon carbide powder is composed of two or more than two different silicon carbide powders with the granularity difference of more than 200 meshes, wherein the silicon carbide content is more than 99.0 percent by weight;
wherein the ceramic composite material powder consists of 1-15 parts by mass of titanium oxide, 1-20 parts by mass of boron-containing compound and 1-15 parts by mass of metal aluminum powder;
the dispersant refers to oleic acid and/or potassium laurate in the amphiphilic compound.
2. The low temperature sintered silicon carbide honeycomb ceramic material of claim 1, wherein the boron containing compound is one or more of borax, sodium borate, boron carbide, titanium boride, boric acid, potassium borate, boron oxide.
3. The low-temperature sintered silicon carbide honeycomb ceramic material as claimed in claim 1, wherein the pore-forming agent is one or more of flour, graphite, potato flour, starch, cellulose, paraffin and PMMA, wherein the cellulose is one or two of carboxymethyl cellulose and hydroxymethyl cellulose.
4. The low-temperature sintered silicon carbide honeycomb ceramic material as claimed in claim 1, wherein the lubricant is one or more of lubricating oil, engine oil, linseed oil and rapeseed oil.
5. The low-temperature sintered silicon carbide honeycomb ceramic material as claimed in claim 1, wherein the extrusion aid is one or more of oleic acid, potassium laurate soap, glycerol, and polyethylene glycol.
6. A method for preparing a low-temperature sintered silicon carbide honeycomb ceramic material, which is used for preparing the low-temperature sintered silicon carbide honeycomb ceramic material as claimed in any one of claims 1 to 5, comprising the steps of:
1) weighing the required components according to the amount, and mixing the pore-forming agent and water into paste by stirring;
2) stirring and mixing silicon carbide powder, ceramic composite material powder and paste, adding a lubricant, a dispersant and an extrusion aid, and stirring to form pug;
3) extruding and molding the pug, and drying to obtain a silicon carbide honeycomb ceramic blank;
4) sequentially carrying out dislocation plugging on the silicon carbide honeycomb ceramic to form a silicon carbide honeycomb ceramic plugging blank;
5) charging the silicon carbide honeycomb ceramic hole plugging blank, and heating to 100-200 ℃ from room temperature at a speed of less than 3 ℃/min; heating to 500-700 ℃ at a speed of less than 2.5 ℃/min, and preserving heat for 1-5 h; heating to 850-1000 ℃ at the speed of less than 2 ℃/min, and keeping the temperature for 1-5 h; heating to 900-1500 ℃ at the speed of less than 3 ℃/min, stopping heating, and cooling to room temperature along with the furnace to prepare the required silicon carbide honeycomb ceramic material.
7. The method for preparing a low-temperature sintered silicon carbide honeycomb ceramic material according to claim 6, wherein the step 5) further comprises the steps of: heating from room temperature to 200 ℃ at a heating rate of 2.2 ℃/min; raising the temperature to 650 ℃ at the heating rate of 1.87 ℃/min, and keeping the temperature for 2 h; heating to 950 ℃ at the speed of 1.67 ℃/min, and keeping the temperature for 2 h; heating to 1100 deg.C at 1.67 deg.C/min, and maintaining for 4 hr; stopping heating, and cooling to room temperature along with the furnace to prepare the required silicon carbide honeycomb ceramic material.
8. The low-temperature sintered silicon carbide honeycomb ceramic material prepared by the preparation method of claim 6 or 7 is characterized in that the coefficient of thermal expansion of the silicon carbide honeycomb ceramic material is 3.5-4.9 × 10 from room temperature to 800 DEG C-6℃-1(ii) a The diameter of the micropores is 5-32um, the median pore diameter is 10-20um, and the pore volume is 0.3-0.35 cc/g; the porosity is 43-55%; the wall thickness is 0.1-0.55mm, the mechanical strength is more than or equal to 8MPa in the axial direction, more than or equal to 1.5MPa in the transverse direction, and more than or equal to 0.3MPa in the 45-degree direction.
9. The silicon carbide particle trap is characterized in that the silicon carbide particle trap is formed by splicing the silicon carbide honeycomb ceramic materials prepared by the preparation method of claim 6 or 7 by using an adhesive.
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| CN108751999A (en) * | 2018-07-05 | 2018-11-06 | 蚌埠威尔特滤清器有限公司 | A kind of honeycomb ceramic carrier and preparation method thereof |
| CN109265172A (en) * | 2018-08-30 | 2019-01-25 | 济宁泉达实业有限责任公司 | A kind of high-performance Si3N4In conjunction with SiC ceramic honey comb and preparation method thereof |
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| CN110526713B (en) * | 2019-08-27 | 2022-03-11 | 广东工业大学 | Porous silicon carbide ceramic and preparation method and application thereof |
| CN111574203A (en) * | 2020-05-18 | 2020-08-25 | 江苏省宜兴非金属化工机械厂有限公司 | Porous ceramic material and preparation method thereof |
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