CN108059449A - 一种高长径比莫来石晶须陶瓷材料的制备方法 - Google Patents

一种高长径比莫来石晶须陶瓷材料的制备方法 Download PDF

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CN108059449A
CN108059449A CN201711411333.3A CN201711411333A CN108059449A CN 108059449 A CN108059449 A CN 108059449A CN 201711411333 A CN201711411333 A CN 201711411333A CN 108059449 A CN108059449 A CN 108059449A
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crystal whisker
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肖卓豪
孔令兵
李秀英
董晓烽
罗文艳
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Jingdezhen Ceramic Institute
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Abstract

本发明涉及一种高长径比莫来石晶须陶瓷材料的制备方法，其特征在于按以下重量百分比配方组成：石英玻璃粉20～26%、Al2O3 72～78%、Y2O3 0.5～2.0%、金属钨粉0.5～2.0%、非晶硅粉0.5～2.0%，经原料混合、初磨、复磨、过筛、压制成型、烧成、自然冷却获得高长径比莫来石晶须陶瓷材料。本发明克服现有技术的不足，在现有原位制备莫来石陶瓷材料的组成配方和工艺基础上，适当添加无毒副作用的添加剂，并通过对部分原料进行预处理和制备工艺优化，获得原位形成以高长径比莫来石晶须为主晶相的陶瓷材料。所制备的陶瓷材料相对坯体的收缩率在5%以内，具有较低的导热系数和较高的孔隙率同时拥有较好的机械强度。

Description

一种高长径比莫来石晶须陶瓷材料的制备方法
技术领域
本发明涉及新材料技术领域，尤其涉及一种高长径比莫来石晶须陶瓷材料的制备方法，可广泛应用于隔热保温与高温过滤等工业领域。
背景技术
莫来石陶瓷是一种非常重要的硅酸铝陶瓷材料，是SiO2-Al2O3体系中唯一稳定的物相，具有良好的高温热稳定性、高温强度、优秀的抗氧化性和较低的热膨胀系数，广泛应用于隔热保温及高温过滤等工业领域。莫来石晶须是指具有较高长径比的莫来石单晶，由于晶须之间的彼此交织生长从而使得以莫来石晶须为主晶相的陶瓷材料在不仅具有较低的密度、较大的孔隙率的同时也具有较高的强度，这是其他多孔材料难以获得的宝贵性能。然而，由于组成及制备工艺等方面的原因，莫来石陶瓷中经常有非莫来石晶体的杂相存在，不仅降低了其使用温度，而且在很大程度上限制了莫来石晶须的生长，使得莫来石晶体只能生长为颗粒状或短棒状，无法生长成高长径比的晶须。
当前制备莫来石晶须时一般都采用气相传质的方式，即在原料中添加氟化铝或氯化铝等高温下容易产生气相的添加物，其中氟化铝一般被认为是获得高性能莫来石陶瓷材料所必需的添加剂。如Perera等（Perera et al, 1985）在1400℃以上的高温烧成高岭石制得莫来石晶须，其最大长径比达8，晶须的长度达到5μm；Katsuki等（Katsuki et al, 1988）把高岭石等原料加热到1700℃，得到长达20 μm的莫来石晶须；江伟辉等（无机材料学报，2010）采用非水解溶胶凝胶法制备了长径比高达70的莫来石晶须材料。然而，以上制备过程基本都离不开采用氟化铝或氯化铝为添加剂，这些添加剂在高温下形成的高温蒸汽是一种致癌物质，不仅在生产过程中对生产人员造成潜在的身体伤害，对环境也造成很大的污染。此外，莫来石晶须在生产与加工过程中若飘散在空中一旦通过呼吸道进入人体，就会在肺部长期留存，由于其细长的针状结构深入人体组织后不再可能脱离，从而对组织器官形成永久性伤害。
因此，单纯的莫来石晶须的制备已逐渐被当代材料制备工业所淘汰，原位制备以莫来石晶须为主晶相的莫来石陶瓷材料逐渐成为市场的主流。同时，研究替代具有很大毒副作用氟化铝的新型添加剂也在不断开发当中，如Yb2O3、Fe2O3、Co2O3、NiO、Er2O3、La2O3、NaH2PO4等均有作为莫来石陶瓷生产过程中矿化剂的报道。然而，采用这些矿化剂所制备的原位生成莫来石晶须的莫来石陶瓷材料由于杂相的存在很难获得高长径比、高纯的莫来石相。如何通过配方改进与工艺优化，使得不添加毒副作用添加剂的情况下原位获得高纯、高长径比莫来石晶须的陶瓷是材料科学工作者的当务之急。
发明内容
本发明要解决的技术问题是提供一种可广泛应用于隔热保温与高温过滤等工业领域的高长径比莫来石晶须陶瓷材料的制备方法。
为解决以上技术问题，本发明的技术方案是：一种高长径比莫来石晶须陶瓷材料的制备方法，其特征在于按以下重量百分比配方组成：石英玻璃粉20～26%、Al2O3 72～78%、Y2O3 0.5～2.0%、金属钨粉0.5～2.0%、非晶硅粉0.5～2.0%，经原料混合、初磨、复磨、过筛、压制成型、烧成、自然冷却获得高长径比莫来石晶须陶瓷材料。
所述原料杂质中K2O和Na2O的重量百分比含量之和少于0.5 %。
所述石英玻璃粉中SiO2的重量百分比含量大于98%，Al2O3的纯度大于97%，Y2O3的纯度大于99%，金属钨粉的纯度大于99%，非晶硅中Si的重量百分比含量不低于98%。
所述原料颗粒度都小于200目。
所述初磨工序中球磨子与原料的质量比为1～5:1，球磨转速为200～400 r/min，球磨时间为1～2小时；所述球磨子为氧化锆材质。
所述复磨工序中球磨子与原料的质量比为20～50:1，球磨转速为200～400 r/min，球磨时间为4～6小时；所述球磨子为碳化钨材质。
所述初磨和复磨过程中不添加水或其他介质，每球磨1小时后停机自然冷却0.5小时。
所述过筛的目数为200目。
所述压制成型的成型压力为30～120 Mpa。
所述烧成工序中的烧结温度为1150～1550℃，升温速率2～15℃/min，保温时间为2～6小时。
本发明具有以下有益效果：
(1) 采用本发明方法制备的莫来石陶瓷，具有较高的机械性能，其抗折强度大于5.4MPa，有利于工程施工与运输；烧结线收缩率小于0.5%，有利于烧结产品的尺寸稳定性；
(2) 采用本发明方法制备的莫来石陶瓷，其晶相组成中仅有莫来石晶相，没有检测出其他晶相存在，测试结果见附图1。高纯莫来石晶相组成有利于其耐热性能的提高，所制备的莫来石陶瓷产品的使用温度可达1700℃；
(3) 本发明所制备的莫来石陶瓷中的莫来石晶须具有高长径比，晶须之间彼此交错形成发达的孔隙，有利于其导热系数的降低，实测表明其导热系数小于0.06 W/m·K。该莫来石晶须直径可达3um，长径比可到28以上，且晶须之间相互咬合，形成互锁结构，因而有利于其机械性能的提高；
(4) 本发明在制备莫来石陶瓷产品过程中无需添加有毒副作用的氟化物或氯化物等矿化剂，消除了对生产人员健康的威胁和对环境的潜在污染。此外，莫来石晶须在陶瓷材料中原位生长，且陶瓷产品具有良好的尺寸稳定性，从而避免了晶须在二次加工过程中对操作人员健康的损害。
附图说明
图1是实施例一所制备陶瓷材料的X射线衍射谱；
图2为实施例一所制备陶瓷材料的扫描电子显微镜图片。
具体实施方式
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效，以下结合较佳实施例，对依据本发明提出的一种高长径比莫来石晶须陶瓷材料的制备方法的具体实施方式、方法、步骤、特征及其功效，详细说明如下：
实施例一：
本实施例为一种以高长径比莫来石晶须为主晶相的陶瓷材料合成方法，其步骤如下：
(1) 所述的莫来石陶瓷材料含有以下重量组分：石英玻璃粉 22%，Al2O3 75%，Y2O3 1.0%，金属钨粉1.0 %，非晶硅粉1.0 %，杂质中K2O和Na2O的含量之和少于0.5 %。
(2) 以上原料中石英玻璃粉要求SiO2含量大于98%，Al2O3纯度大于97%，Y2O3金属钨粉纯度大于99%，非晶硅中Si含量不低于98%，所有原料过200目标准筛。
(3) 按比例准确称量、混合均匀后先采用氧化锆球磨子进行初步球磨，球磨仔与混合料的质量比为2:1，球磨转速400 r/min，球磨时间为1小时；然后再采用碳化钨球磨子进行高能球磨，球磨子与混合料的质量比为25:1，球磨转速300 r/min，球磨时间为4.5小时，球磨过程中不添加水或其他介质，为防止球磨过程中过度发热，每球磨1小时后停机自然冷却0.5小时。
(4) 将球磨后的混合物再次过200目标准筛，采用压制成型的方式制备坯体，成型压力为50 MPa。
(5) 成型后的坯体于密闭窑炉中进行烧结，烧结温度为1350℃，升温速率8 ℃/min；保温时间为3小时，自然冷却后得到以莫来石晶须为主晶相的高性能莫来石陶瓷。
(6) 采用本发明方法制备的莫来石陶瓷，其晶相组成中全部为莫来石，没有其他晶相存在，莫来石晶须长径比可达31，莫来石陶瓷的抗折强度为6.1 MPa，烧结线收缩率为0.42 %，导热系数为0.056 W/m·K。
图1中的衍射谱中可见未有任何其他杂相存在，所有衍射峰均来自于莫来石晶体。
图2中莫来石晶须直径达1-3um，长径比达35以上，且晶须之间彼此相互咬合，形成互锁结构，从而赋予其很好的机械性能。
实施例二：
本实施例为一种以高长径比莫来石晶须为主晶相的陶瓷材料合成方法，其步骤如下：
(1) 所述的莫来石陶瓷材料含有以下重量组分：石英玻璃粉 25%，Al2O3 73%，Y2O3 0.7%，金属钨粉0.5 %，非晶硅粉0.8 %。杂质中K2O和Na2O的含量之和少于0.5 %。
(2) 以上原料中石英玻璃粉要求SiO2含量大于98%，Al2O3纯度大于97%，Y2O3金属钨粉纯度大于99%，非晶硅中Si含量不低于98%，所有原料过200目标准筛。
(3) 按比例准确称量、混合均匀后先采用氧化锆球磨子进行初步球磨，球磨仔与混合料的质量比为4:1，球磨转速200 r/min，球磨时间为1.5小时；然后再采用碳化钨球磨子进行高能球磨，球磨子与混合料的质量比为50:1，球磨转速400 r/min，球磨时间为6小时，球磨过程中不添加水或其他介质。为防止球磨过程中过度发热，每球磨1小时后停机自然冷却0.5小时。
(4) 将球磨后的混合物再次过200目标准筛，采用压制成型的方式制备坯体，成型压力为90 MPa。
(5) 成型后的坯体于密闭窑炉中进行烧结，烧结温度为1520℃，升温速率12 ℃/min；保温时间为6小时，自然冷却后得到以莫来石晶须为主晶相的高性能莫来石陶瓷。
(6) 采用本发明方法制备的莫来石陶瓷，其晶相组成中全部为莫来石，没有其他晶相存在，莫来石晶须长径比可达35。莫来石陶瓷的抗折强度为6.7 MPa，烧结线收缩率为0.37 %，导热系数为0.046 W/m·K。

Claims (10)

1.一种高长径比莫来石晶须陶瓷材料的制备方法，其特征在于按以下重量百分比配方组成：石英玻璃粉20～26%、Al2O3 72～78%、Y2O3 0.5～2.0%、金属钨粉0.5～2.0%、非晶硅粉0.5～2.0%，经原料混合、初磨、复磨、过筛、压制成型、烧成、自然冷却获得高长径比莫来石晶须陶瓷材料。
2.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述原料杂质中K2O和Na2O的重量百分比含量之和少于0.5 %。
3.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述石英玻璃粉中SiO2的重量百分比含量大于98%，Al2O3的纯度大于97%，Y2O3的纯度大于99%，金属钨粉的纯度大于99%，非晶硅中Si的重量百分比含量不低于98%。
4.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述原料颗粒度都小于200目。
5.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述初磨工序中球磨子与原料的质量比为1～5:1，球磨转速为200～400 r/min，球磨时间为1～2小时；所述球磨子为氧化锆材质。
6.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述复磨工序中球磨子与原料的质量比为20～50:1，球磨转速为200～400 r/min，球磨时间为4～6小时；所述球磨子为碳化钨材质。
7.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述初磨和复磨过程中不添加水或其他介质，每球磨1小时后停机自然冷却0.5小时。
8.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述过筛的目数为200目。
9.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述压制成型的成型压力为30～120 Mpa。
10.根据权利要求1所述的高长径比莫来石晶须陶瓷材料的制备方法，其特征在于：所述烧成工序中的烧结温度为1150～1550℃，升温速率2～15℃/min，保温时间为2～6小时。
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