CN108249900B - 高性能Al2O3-SiC-C质浇注料用添加剂及其制备方法 - Google Patents
高性能Al2O3-SiC-C质浇注料用添加剂及其制备方法 Download PDFInfo
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- 238000002360 preparation method Methods 0.000 title claims abstract description 12
- 239000000654 additive Substances 0.000 claims abstract description 43
- 230000000996 additive effect Effects 0.000 claims abstract description 40
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 27
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 24
- 239000000843 powder Substances 0.000 claims abstract description 23
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 18
- 229910001845 yogo sapphire Inorganic materials 0.000 claims abstract description 13
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 10
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 9
- 239000006229 carbon black Substances 0.000 claims abstract description 6
- 150000004767 nitrides Chemical class 0.000 claims abstract description 6
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910001691 hercynite Inorganic materials 0.000 claims abstract description 5
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims abstract description 5
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 5
- 229910000519 Ferrosilicon Inorganic materials 0.000 claims abstract description 4
- 238000002156 mixing Methods 0.000 claims description 13
- 238000004806 packaging method and process Methods 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 238000011049 filling Methods 0.000 claims description 5
- 238000007789 sealing Methods 0.000 claims description 5
- 238000005303 weighing Methods 0.000 claims description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 4
- 229910015372 FeAl Inorganic materials 0.000 claims description 2
- 229910052757 nitrogen Inorganic materials 0.000 claims description 2
- 235000012239 silicon dioxide Nutrition 0.000 claims 1
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 abstract description 31
- 229910052742 iron Inorganic materials 0.000 abstract description 15
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 abstract description 14
- 229910052863 mullite Inorganic materials 0.000 abstract description 14
- 230000003628 erosive effect Effects 0.000 abstract description 10
- 239000002893 slag Substances 0.000 abstract description 8
- 238000004901 spalling Methods 0.000 abstract description 7
- 239000011159 matrix material Substances 0.000 abstract description 4
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- 238000001764 infiltration Methods 0.000 abstract description 3
- 238000010952 in-situ formation Methods 0.000 abstract description 2
- 239000010431 corundum Substances 0.000 description 15
- 239000011777 magnesium Substances 0.000 description 14
- 229910052749 magnesium Inorganic materials 0.000 description 14
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 14
- 229910010271 silicon carbide Inorganic materials 0.000 description 14
- 229910052596 spinel Inorganic materials 0.000 description 14
- 239000011029 spinel Substances 0.000 description 14
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 12
- 239000000463 material Substances 0.000 description 12
- 150000004645 aluminates Chemical class 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 8
- 239000003638 chemical reducing agent Substances 0.000 description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 6
- 229910052580 B4C Inorganic materials 0.000 description 5
- 229910052782 aluminium Inorganic materials 0.000 description 5
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 5
- 238000005266 casting Methods 0.000 description 5
- 239000004568 cement Substances 0.000 description 5
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- 239000002184 metal Substances 0.000 description 5
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 4
- 239000003963 antioxidant agent Substances 0.000 description 4
- 230000003078 antioxidant effect Effects 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 239000010443 kyanite Substances 0.000 description 4
- 229910052850 kyanite Inorganic materials 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 229910052710 silicon Inorganic materials 0.000 description 4
- 239000010703 silicon Substances 0.000 description 4
- 239000011863 silicon-based powder Substances 0.000 description 4
- 238000005336 cracking Methods 0.000 description 3
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- -1 magnesium aluminate Chemical class 0.000 description 2
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- 230000035939 shock Effects 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
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- 238000001816 cooling Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
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- 229910001337 iron nitride Inorganic materials 0.000 description 1
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 235000014380 magnesium carbonate Nutrition 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 229910000734 martensite Inorganic materials 0.000 description 1
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- 239000000203 mixture Substances 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 238000009740 moulding (composite fabrication) Methods 0.000 description 1
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- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
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- 230000009467 reduction Effects 0.000 description 1
- 238000010079 rubber tapping Methods 0.000 description 1
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 235000019832 sodium triphosphate Nutrition 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
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Abstract
本发明涉及一种高性能Al2O3‑SiC‑C质浇注料用添加剂及其制备方法。所述添加剂,按重量份计,包含:铁铝尖晶石5~9份,炭黑1~3份,二氧化硅微粉1~3份,氧化铝微粉3~6份,二氧化锆2~4份,氮化硅铁1~3份,以及镁砂1~2份。本发明的添加剂当加入到Al2O3‑SiC‑C质浇注料中,使浇注料具有良好的结构柔韧性,有效降低浇注料的脆性,提高了抗剥落性;有效抵抗铁水的浸润,减小侵蚀;原位形成的SiC和莫来石,可形成网络结构,提高结合强度,强化基质;氮化物的加入和原位形成提高了抗侵蚀性和冲击性,添加剂的引入,提高了浇注料结构韧性、抗剥落性、耐磨性和抗渣铁侵蚀性,延长了Al2O3‑SiC‑C质浇注料的使用寿命。
Description
技术领域
本发明涉及一种高炉炼铁用高性能Al2O3-SiC-C质浇注料用添加剂及其制备方法,属于高炉炼铁用耐火材料技术领域。
背景技术
目前高炉炼铁系统用耐材主要采用Al2O3-SiC-C质浇注料,包括炉缸、主沟、渣沟、铁沟、摆动溜槽、鱼雷罐等部位。其损毁机理主要在于四方面:高温热应力造成材料的剥落和龟裂;高温渣铁液的冲刷磨损;材料与高炉渣反应生成低共熔物而熔蚀;材料的氧化损毁。
随着高炉炼铁向大型、高效、自动和长寿化方向发展,国内外高炉逐渐采用高温风、高顶压、高富氧量、碳氢化合物及喷吹煤粉等新技术,高炉产量提高,同时伴随着渣铁处理量的增加,出铁速率加快,对炼铁系统用 Al2O3-SiC-C质浇注料侵蚀速率加快,冲刷破坏程度愈来愈严重,现有浇注料已经不能满足炼铁技术发展的要求,所以对高性能Al2O3-SiC-C质浇注料的研究迫在眉睫,对高炉长寿发展、节能降耗、缩短与发达国家炼铁技术水平的差距,都具有十分重要的意义。
发明内容
鉴于上述问题,本发明的目的在于提供一种高性能Al2O3-SiC-C质浇注料用添加剂,以提高浇注料的结构韧性,强化基质,提高了抗剥落性和抗渣铁浸润性,延长了Al2O3-SiC-C质浇注料的使用寿命,满足高炉炼铁技术发展的需求。
本发明的还一目的在于提供上述高性能Al2O3-SiC-C质浇注料用添加剂的制备方法。
为了实现上述目的,本发明采用如下的技术方案:
根据本发明的一个方面,本发明提供的高性能Al2O3-SiC-C质浇注料用添加剂,按重量份计,包含:
下面,更具体地说明本发明的高性能Al2O3-SiC-C质浇注料用添加剂。
在本发明优选的实施方案中,其中:
所述铁铝尖晶石,其FeAl2O4含量≥95wt%,为粉料,要求粒度≤74μm;
所述炭黑,其碳含量≥99wt%;
所述二氧化硅微粉,其SiO2含量≥93wt%,平均粒径D50为0.1~0.3μm;
所述氧化铝微粉,其Al2O3含量≥99wt%,平均粒径D50为1~3μm;
所述二氧化锆,其ZrO2含量≥99wt%,为粉料,要求粒度≤74μm;
所述氮化硅铁,其总氮TN含量为27wt%~32wt%,Fe含量为11wt%~ 15wt%,为粉料,要求粒度为≤74μm;
所述镁砂,其MgO含量≥95wt%,为粉料,要求粒度≤74μm。
根据本发明的另一个方面,本发明提供的高性能Al2O3-SiC-C质浇注料用添加剂的制备方法,包括:将添加剂的各组分按其重量份称量,倒入倾斜式搅拌机中混合,转子转速控制在135r/min~153r/min,混合时间控制在3~5 分钟,混合后即得该添加剂,而后装入防水包装袋中密封保存。
本发明所提供的高性能Al2O3-SiC-C质浇注料用添加剂,当用于 Al2O3-SiC-C质浇注料,具有如下创新性和有益效果:
(1)本发明添加剂引入的铁铝尖晶石具有高温的结构柔韧性,在高温下与镁砂进行Fe2+和Mg2+离子互扩散,形成镁铝尖晶石,同时伴随着体积膨胀促进微裂纹的形成,微裂纹可以吸收主裂纹扩展的能量,可有效阻止裂纹的扩展;引入的二氧化锆,在温度变化时,会发生的马氏体相变,吸收了能量,提高了断裂能,从而提高了断裂韧性,抑制裂纹的扩展。所以,这三种物质的复配可有效降低浇注料的脆性,提高了浇注料的结构韧性和抗剥落性。
(2)本发明添加剂引入的炭黑,碳含量高,灰分小,保证高温环境下的化学稳定性,有效地抵抗铁水的浸润,减小侵蚀,同时还与Al2O3-SiC-C质浇注料中的金属硅反应生成SiC,这种原位形成的SiC结合强度高,更有利于抗铁水的冲刷。
(3)本发明添加剂引入的氧化铝微粉和二氧化硅微粉,可在高温下反应生成针棒状或晶须状的莫来石的网络结构,可有效提高结构强度,提高抗热震性和抗冲刷性。
(4)本发明添加剂引入的氮化硅铁,含有氮化硅,硬度高,熔点高,导热性好,含有少量的Fe,可以与炭黑反应生成SiC和N2,N2可与浇注料中的金属硅反应生成Si3N4,提高浇注料的导热性,抗金属铁液的侵蚀。
本发明的添加剂当加入到Al2O3-SiC-C质浇注料中,使浇注料具有良好的结构柔韧性,有效降低浇注料的脆性,提高了抗剥落性;有效抵抗铁水的浸润,减小侵蚀;原位形成的SiC和莫来石,可形成网络结构,提高结合强度,强化基质;氮化物的加入和原位形成提高了抗侵蚀性和冲击性,添加剂的引入,提高了浇注料结构韧性、抗剥落性、耐磨性和抗渣铁侵蚀性,延长了 Al2O3-SiC-C质浇注料的使用寿命。
具体地,加入了本发明添加剂的摆动溜槽用的Al2O3-SiC-C质浇注料,按重量份计,包含:
所述含镁铝尖晶石刚玉,是氧化铝基镁质复相材料,可以按照如下方法得到:以工业氧化铝粉为主料,氧化镁粉为添加剂,经细磨、成型、干燥,在1750~1950℃温度下烧结而成,在反应过程中生成的镁铝尖晶石相,嵌入在刚玉相中,形成的含镁铝尖晶石刚玉,应用在耐火材料中,相比普通烧结刚玉具有较好的强度、抗热震性、抗剥落性、抗渣性和骨料与基质结合性增强。本发明的含镁铝尖晶石刚玉,要求Al2O3含量≥96wt%,MgO含量≤4wt%,级配为:8mm~5mm 10~15份,5mm~3mm 10~15份,3mm~1mm 10~15 份,1mm~0.2mm 10~15份,粒度≤0.074mm 10~15份。
所述碳化硅,其SiC含量≥97wt%,级配为:3mm~1mm 0~5份,1mm~ 0.2mm 5~7份,粒度≤0.074mm 5~8份。
所述莫来石为电熔莫来石,其Al2O3含量≥70wt%,级配为:5mm~3mm 0~3份,3mm~1mm 1~2份,1mm~0.2mm 2~5份,粒度≤0.074mm 2~5 份。
所述铝酸盐水泥,其Al2O3含量≥77wt%。
所述蓝晶石,其粒度≤0.5mm。
所述减水剂,例如可以为德国巴斯夫FS65型高效减水剂。
所述复合抗氧化剂,按重量份计,组成如下:金属硅粉0.5~1.5份,碳化硼0.5~1.5份,其中,所述金属硅粉,其Si含量≥95wt%,为粉料,要求粒度≤74μm;所述碳化硼,其B4C含量≥95wt%,为粉料,要求粒度≤74μm。
传统的摆动溜槽用Al2O3-SiC-C质浇注料与加入本发明添加剂的摆动溜槽用Al2O3-SiC-C质浇注料使用情况对比见表1:
其中,传统摆动溜槽浇注料主要组分包括:矾土;棕刚玉;碳化硅;沥青粉;铝酸盐水泥;硅微粉;金属铝粉;三聚磷酸钠等。
表1
由表1可见,加入本发明添加剂的摆动溜槽浇注料相比传统的摆动溜槽浇注料,有较高的结合强度,抗冲刷耐磨性好;体积稳定性好,抗剥落抗开裂性好;使用寿命大幅提高。
具体实施方式
下面结合具体实施例对本发明作进一步的描述,下述各实施例仅用于说明本发明,而本发明的范围并不局限于这些具体实施例中。
含镁铝尖晶石刚玉的制备:
以工业氧化铝粉为主料,氧化镁粉为添加剂,经细磨、成型、干燥,在1750~1950℃温度下烧结而成,在反应过程中生成的镁铝尖晶石相,嵌入在刚玉相中,冷却,破碎得到各粒度的含镁铝尖晶石刚玉,其中Al2O3含量约 97.5wt%,MgO含量约2.5wt%。
一、高性能Al2O3-SiC-C质浇注料用添加剂的制备
实施例1-实施例3
在实施例1-3中,将添加剂的各组分按表2所示的重量份准确称量,倒入倾斜式搅拌机中混合,转子转速控制在135-153r/min,混合时间控制在3-5分钟,混合后所得添加剂即可装入防水包装袋中密封保存。
表2添加剂的组成
项目 | 实施例1 | 实施例2 | 实施例3 |
铁铝尖晶石 | 5 | 7 | 9 |
炭黑 | 2 | 2 | 2 |
二氧化硅微粉 | 2 | 2 | 2 |
氧化铝微粉 | 4 | 4 | 4 |
二氧化锆 | 3 | 3 | 3 |
氮化硅铁 | 1 | 2 | 3 |
镁砂 | 2 | 2 | 2 |
二、采用本发明的添加剂制备摆动溜槽浇注料
浇注料制备例1
其组分及重量份为:含镁铝尖晶石刚玉57份;碳化硅15份;莫来石5 份;铝酸盐水泥1.9份;蓝晶石1份;复合抗氧化剂1份(金属硅粉0.5份;碳化硼0.5份);减水剂FS65型高效减水剂0.1份;以及采用上述实施例1制备的添加剂19份。
其中,含镁铝尖晶石刚玉级配为:8mm~5mm 10份,5mm~3mm 12份, 3mm~1mm 12份,1mm~0.2mm 10份,粒度≤0.074mm 13份;
碳化硅级配为:3mm~1mm 5份,1mm~0.2mm 5份,粒度≤0.074mm 5 份;
莫来石为电熔莫来石,级配为:3mm~1mm 1份,1mm~0.2mm 2份,粒度≤0.074mm 2份。
将浇注料的各组分按其重量份称量,倒入倾斜式搅拌机中混合,转子转速控制在117-135r/min,混合时间控制在3-5分钟,混合后所得浇注料即可装入防水包装袋中密封保存。
浇注料制备例2
其组分及重量份为:含镁铝尖晶石刚玉54份;碳化硅15份;莫来石5 份;铝酸盐水泥1.9份;蓝晶石1份;复合抗氧化剂1份(金属硅粉0.5份;碳化硼0.5份);减水剂FS65型高效减水剂0.1份;以及采用上述实施例2制备的添加剂22份。
其中,含镁铝尖晶石刚玉级配为:8mm~5mm 10份,5mm~3mm 12份, 3mm~1mm 12份,1mm~0.2mm 10份,粒度≤0.074mm 10份;
碳化硅级配为:3mm~1mm 5份,1mm~0.2mm 5份,粒度≤0.074mm 5 份;
莫来石为电熔莫来石级配为:3mm~1mm 1份,1mm~0.2mm 2份,粒度≤0.074mm 2份。
将浇注料的各组分按其重量份称量,倒入倾斜式搅拌机中混合,转子转速控制在117-135r/min,混合时间控制在3-5分钟,混合后所得浇注料即可装入防水包装袋中密封保存。
浇注料制备例3
其组分及重量份为:含镁铝尖晶石刚玉51份;碳化硅15份;莫来石5 份;铝酸盐水泥1.9份;蓝晶石1份;复合抗氧化剂1份(金属硅0.5份;碳化硼0.5份);减水剂FS65型高效减水剂0.1份;以及采用上述实施例3制备的添加剂25份。
其中,含镁铝尖晶石刚玉级配为:8mm~5mm 10份,5mm~3mm 10份, 3mm~1mm 11份,1mm~0.2mm 10份,粒度≤0.074mm 10份;
碳化硅级配为:3mm~1mm 5份,1mm~0.2mm 5份,粒度≤0.074mm 5 份;
莫来石为电熔莫来石,级配为:3mm~1mm 1份,1mm~0.2mm 2份,粒度≤0.074mm 2份。
将浇注料的各组分按其重量份称量,倒入倾斜式搅拌机中混合,转子转速控制在117-135r/min,混合时间控制在3-5分钟,混合后所得浇注料即可装入防水包装袋中密封保存。
将浇注料制备例1-3制备的浇注料,加入适量水搅拌均匀后浇注到 40×40×160mm三联模具中,脱模后于110℃烘烤24小时,1450℃埋炭保温3 小时。分别按照标准YB/T5200、GB/T3001、GB/T 5072、GB/T 5988检测试样体积密度、抗折强度、耐压强度、线变化率,检测结果见表3:
表3采用本发明添加剂制备的摆动溜槽浇注料性能指标
由表3可见,采用本发明添加剂制备的摆动溜槽浇注料具有良好结合强度,烧结性好,结构柔韧性好,抗开裂效果好,在实际应用过程中,通铁量达到了15~18万吨,使用寿命相比传统摆动溜槽用浇注料提高约1倍。
Claims (6)
2.根据权利要求1所述的高性能Al2O3-SiC-C质浇注料用添加剂,其特征是,所述炭黑,其碳含量≥99wt%。
3.根据权利要求1所述的高性能Al2O3-SiC-C质浇注料用添加剂,其特征是,所述二氧化硅微粉,其SiO2含量≥93wt%,平均粒径D50为0.1~0.3μm。
4.根据权利要求1所述的高性能Al2O3-SiC-C质浇注料用添加剂,其特征是,所述氧化铝微粉,其Al2O3含量≥99wt%,平均粒径D50为1~3μm。
5.根据权利要求1所述的高性能Al2O3-SiC-C质浇注料用添加剂,其特征是,所述氮化硅铁,其总氮TN含量为27wt%~32wt%,Fe含量为11wt%~15wt%,为粉料,粒度为≤74μm。
6.如权利要求1所述的高性能Al2O3-SiC-C质浇注料用添加剂的制备方法,包括:将添加剂的各组分按其重量份称量,倒入倾斜式搅拌机中混合,转子转速控制在135r/min~153r/min,混合时间控制在3~5分钟,混合后即得该添加剂,而后装入防水包装袋中密封保存。
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