CN108395219A - 一种托辊用陶瓷材料及其制备方法 - Google Patents
一种托辊用陶瓷材料及其制备方法 Download PDFInfo
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- 229910010293 ceramic material Inorganic materials 0.000 title claims abstract description 33
- 238000002360 preparation method Methods 0.000 title claims abstract description 19
- 239000002994 raw material Substances 0.000 claims abstract description 33
- 239000006004 Quartz sand Substances 0.000 claims abstract description 32
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 32
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 24
- 239000000919 ceramic Substances 0.000 claims abstract description 20
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims abstract description 17
- 229910001928 zirconium oxide Inorganic materials 0.000 claims abstract description 17
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 16
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 16
- 238000000498 ball milling Methods 0.000 claims abstract description 15
- 239000001768 carboxy methyl cellulose Substances 0.000 claims abstract description 15
- 239000011812 mixed powder Substances 0.000 claims abstract description 15
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 13
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 13
- 238000003825 pressing Methods 0.000 claims abstract description 13
- 239000000454 talc Substances 0.000 claims abstract description 13
- 229910052623 talc Inorganic materials 0.000 claims abstract description 13
- 235000012222 talc Nutrition 0.000 claims abstract description 13
- 238000000227 grinding Methods 0.000 claims abstract description 12
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 claims abstract description 9
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 claims abstract description 9
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 claims abstract description 9
- 238000000748 compression moulding Methods 0.000 claims abstract description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 14
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 12
- 238000012545 processing Methods 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 9
- 238000010792 warming Methods 0.000 claims description 9
- 229910052742 iron Inorganic materials 0.000 claims description 8
- 238000001694 spray drying Methods 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 5
- 239000002002 slurry Substances 0.000 claims description 3
- 238000005245 sintering Methods 0.000 claims description 2
- 239000004411 aluminium Substances 0.000 claims 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims 1
- 229910052782 aluminium Inorganic materials 0.000 claims 1
- 238000002156 mixing Methods 0.000 claims 1
- 230000003647 oxidation Effects 0.000 claims 1
- 238000007254 oxidation reaction Methods 0.000 claims 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 abstract description 21
- 239000011268 mixed slurry Substances 0.000 description 10
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 6
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 6
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 238000005452 bending Methods 0.000 description 5
- 238000010521 absorption reaction Methods 0.000 description 4
- 238000007605 air drying Methods 0.000 description 4
- 238000007664 blowing Methods 0.000 description 4
- 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 description 4
- 229910052863 mullite Inorganic materials 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000005498 polishing Methods 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- 239000011734 sodium Substances 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 230000003078 antioxidant effect Effects 0.000 description 2
- 235000006708 antioxidants Nutrition 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000011065 in-situ storage Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 238000007088 Archimedes method Methods 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 101100371219 Pseudomonas putida (strain DOT-T1E) ttgE gene Proteins 0.000 description 1
- 229910003978 SiClx Inorganic materials 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000003556 assay Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 230000003139 buffering effect Effects 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000007788 roughening Methods 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000002352 surface water Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
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Abstract
本发明实施例提供了一种托辊用陶瓷材料的制备方法，包括：(1)称取原料，原料包括如下组分：氧化铝41‑47％、铝矾土21.5‑23.5％、石英砂12.5‑14.5％、氧化锆1.7‑2.1％、碳化硅7.0‑7.5％、钾长石4.6‑5.0％、滑石4.6‑5.0％、氧化镁1.0‑1.25％、羧甲基纤维素钠0.1‑0.15％；(2)将所述原料进行湿法球磨，球磨结束后干燥处理，得到混合粉体；(3)将所述混合粉体装入模具后采用冷等静压工艺压制成型，得到陶瓷坯体；(4)将所述陶瓷坯体于1450‑1550℃烧结0.5‑3小时。应用本发明的托辊用陶瓷材料的制备方法，制备的陶瓷材料的断裂韧性明显高于普通的陶瓷托辊。
Description
技术领域
本发明涉及陶瓷材料技术领域，特别是涉及一种托辊用陶瓷材料及其制备方法。
背景技术
带式输送机是矿山、粮储、建材、港口、电力等行业普遍采用的输送设备，而托辊是其重要的配件之一，对输送带起到支撑作用，提高货物的输送量、缓冲货物对输送带的冲击作用，托辊的性能直接影响到输送带的寿命及输送量。现有技术中普遍采用钢制托辊,钢制托辊不仅重,增加了更换时的劳动强度，而且耐磨性差，容易缺损或变形不平整而磨损皮带。塑料(例如尼龙)托辊虽然质轻、价廉，但是耐候、耐磨等性能较差。
普通的陶瓷托辊是用粘土烧结而成，具有耐磨、耐腐蚀、抗氧化、运行稳定性高等优点，可有效防止皮带跑偏，减少皮带的局部磨损，延长皮带使用寿命，陶瓷托辊的使用寿命远比普通钢质托辊和塑料托辊长。此外，陶瓷托辊的耐高温、抗氧化、耐腐蚀能力强，适用于各种恶劣环境，但普通的陶瓷托辊的断裂韧性不超过5.0MPa·m1/2，韧性差等缺点限制了它的应用范围。
发明内容
本发明实施例的目的在于提供一种托辊用陶瓷材料及其制备方法，以解决现有的托辊陶瓷韧性差的问题。具体技术方案如下：
本发明首先提供了一种托辊用陶瓷材料的制备方法，包括：
(1)称取原料，基于所述原料的总质量，所述原料包括以质量分数计的如下组分：氧化铝41-47％、铝矾土21.5-23.5％、石英砂12.5-14.5％、氧化锆1.7-2.1％、碳化硅7.0-7.5％、钾长石4.6-5.0％、滑石4.6-5.0％、氧化镁1.0-1.25％、羧甲基纤维素钠0.1-0.15％；
(2)将所述原料进行湿法球磨，球磨结束后干燥处理，得到混合粉体；
(3)将所述混合粉体装入模具后采用冷等静压工艺压制成型，得到陶瓷坯体；
(4)将所述陶瓷坯体于1450-1550℃烧结0.5-3小时。
在本发明的一些具体实施方式中，步骤(1)中，所述石英砂经过以下预处理：过100-200目筛，然后进行水洗，风干。
在本发明的一些具体实施方式中，步骤(2)中的湿法球磨包括：将所述原料、研磨介质、分散介质置于球磨机中进行球磨12-15小时，然后过200-400目筛。
在本发明的一些具体实施方式中，所述原料、研磨介质、分散介质的质量比例为1:2:1；优选地，所述研磨介质为氧化锆球；所述分散介质为水。
在本发明的一些具体实施方式中，在步骤(2)球磨结束后，对球磨得到的混合浆料用磁铁进行除铁处理。
在本发明的一些具体实施方式中，在步骤(2)中采用喷雾干燥的方式进行干燥处理。
在本发明的一些具体实施方式中，步骤(3)中的冷等静压工艺参数包括：成型压力140-160MPa；保压3-5分钟。
在本发明的一些具体实施方式中，步骤(3)中烧结的升温速率为：以5℃/分钟的升温速率升温至700℃，再以10℃/分钟的升温速率升温至1450-1550℃。
在本发明的一些具体实施方式中，所述石英砂为海南石英砂。
本发明还提供了前述的方法制备的托辊用陶瓷材料。
本发明的托辊用陶瓷材料的制备方法，其利用氧化锆增韧、碳化硅颗粒增韧、原位形成莫来石晶须增韧的原理，通过三者的协同作用提高陶瓷的断裂韧性，使得制备的陶瓷材料的断裂韧性明显高于普通的陶瓷托辊。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明实施例1制备的增韧陶瓷材料断面的扫描电镜图。
具体实施方式
本发明提供了一种托辊用陶瓷材料的制备方法，通过氧化铝、铝矾土、石英砂形成含莫来石相的高铝陶瓷，使材料具有较好的强度；并加入氧化锆和碳化硅作为增韧相，以钾长石、滑石和氧化镁作为烧结助剂，可降低反应温度，加入羧甲基纤维素作为粘结剂便于成型，具体方案如下：
(1)称取原料，基于所述原料的总质量，所述原料包括以质量分数计的如下组分：氧化铝41-47％、铝矾土21.5-23.5％、石英砂12.5-14.5％、氧化锆1.7-2.1％、碳化硅7.0-7.5％、钾长石4.6-5.0％、滑石4.6-5.0％、氧化镁1.0-1.25％、羧甲基纤维素钠0.1-0.15％；
(2)将所述原料进行湿法球磨，球磨结束后干燥处理，得到混合粉体；
(3)将所述混合粉体装入模具后采用冷等静压工艺压制成型，得到陶瓷坯体；
(4)将所述陶瓷坯体于1450-1550℃烧结0.5-3小时。
本发明所采用的原料均可以采用工业级产品，除非有特殊说明，本发明所采用的原料均是陶瓷制备及相关领域的常规原料，本领域技术人员可以通过商业途径购得。
在本发明的一些具体实施方式中，石英砂可以采用海南石英砂，本文中所说的海南石英砂是指产地为海南省的石英砂。海南省的石英砂资源丰富，且海南石英砂的二氧化硅含量更高，杂质更少。较佳地，在应用石英砂来制备陶瓷材料之前，可以先将石英砂预先过100-200目筛，然后进行水洗，自然风干，以去除石英砂中的氯化钠等盐分杂质。当然，也可以直接从商家购买水洗石英砂来实现本发明的技术方案。
在本发明的一些具体实施方式中，步骤(2)中所采用的湿法球磨包括：将所述原料、研磨介质、分散介质置于球磨机中进行球磨12-15小时，放浆时过200-400目筛，得到混合浆料。
在本发明的一些具体实施方式中，所述原料、研磨介质、分散介质的比例为1:2:1；更为具体地，所述研磨介质可以为氧化锆球；所述分散介质可以为水。
由于所用的矿石中含有铁元素的氧化物，如果不去除，则制备出的陶瓷材料会由于铁的存在，而易被腐蚀，进而影响材料的性能。因此较佳地，在步骤(2)球磨结束后，对球磨得到的混合浆料用磁铁棒进行除铁处理，具体例如可以通过磁铁棒搅拌混合浆料，直至磁铁棒上没有铁质杂志吸附在上面；通过磁铁吸附混合浆料中的铁的氧化物。
在本发明的一些具体实施方式中，在步骤(2)中采用喷雾干燥的方式进行干燥处理。将混合浆料投入喷雾干燥塔中，可以通过离心喷雾干燥方式，进行喷雾干燥。由于喷雾干燥出来的干粉呈球形颗粒，更利于混合粉体均匀地装入成型模具。
在本发明的一些具体实施方式中，步骤(3)中的冷等静压工艺参数包括：成型压力140-160MPa；保压3-5分钟。
在本发明的一些具体实施方式中，步骤(3)中烧结的升温速率为：以5℃/分钟的升温速率升温至700℃，再以10℃/分钟的升温速率升温至1450-1550℃；前期采用较慢的升温速率，用于防止排胶过程中坯体开裂；700℃后，快速升温防止由于加热时间过长使材料晶粒粗化。
由本发明提供的上述方法制备的托辊用陶瓷材料，具有强度高、韧性好、耐腐蚀、抗高低温且使用寿命长等优点。
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
首先，需要说明的是，以下各实施例所用的各原料及相关设备，除非有特殊说明，均可以通过商业途径获得。
实施例1托辊用陶瓷材料的制备
(1)准备原料氧化铝、铝矾土、石英砂、氧化锆、碳化硅、钾长石、滑石、氧化镁、羧甲基纤维素钠；并将海南石英砂过150目筛，然后进行水洗，自然风干。
(2)称取原料如下：工业氧化铝8.8g、铝矾土4.4g、海南石英砂2.6g、氧化锆0.4g、碳化硅1.58g、钾长石1g、滑石1g、氧化镁0.2g、羧甲基纤维素钠(CMC)0.02g。
(3)将所有原料按料:氧化锆球:水＝1:2:1的质量比置于球磨机中进行球磨12小时，放浆时通过300目筛进行筛分，得到混合浆料。并用磁铁棒进行除铁处理。
(4)将混合浆料通过喷雾干燥得到具有一定流动性的混合粉体。
(5)将混合粉体装入橡胶模具，采用冷等静压工艺将粉料压制成型，成型压力为140MPa，保压5分钟。
(6)将成型的陶瓷坯体放置在高温马弗炉中，室温至700℃以5℃/分钟升温，然后以10℃/分钟升温至1450℃，保温1小时，试样随炉自然降温得到增韧陶瓷材料。
(7)任选地，将烧结后的材料进行磨抛处理，得到试样成品用于测试。
实施例2托辊用陶瓷材料的制备
(1)准备原料氧化铝、铝矾土、石英砂、氧化锆、碳化硅、钾长石、滑石、氧化镁、羧甲基纤维素钠；并将海南石英砂过150目筛，然后进行水洗，自然风干。
(2)称取原料如下：工业氧化铝8.8g、铝矾土4.4g、海南石英砂2.6g、氧化锆0.4g、碳化硅1.58g、钾长石1g、滑石1g、氧化镁0.2g、羧甲基纤维素钠(CMC)0.02g。
(3)将所有原料按料:氧化锆球:水＝1:2:1的质量比置于球磨机中进行球磨13小时，放浆时通过300目筛进行筛分，得到混合浆料。并用磁铁棒进行除铁处理。
(4)将混合浆料通过喷雾干燥得到具有一定流动性的混合粉体。
(5)将混合粉体装入橡胶模具，采用冷等静压工艺将粉料压制成型，成型压力为160MPa，保压3分钟。
(6)将成型的陶瓷坯体放置在高温马弗炉中，室温至700℃以5℃/分钟升温，然后以10℃/分钟升温至1450℃，保温1小时，试样随炉自然降温得到增韧陶瓷材料。
(7)任选地，将烧结后的材料进行磨抛处理，得到试样成品用于测试。
实施例3托辊用陶瓷材料的制备
(1)准备原料氧化铝、铝矾土、石英砂、氧化锆、碳化硅、钾长石、滑石、氧化镁、羧甲基纤维素钠；并将海南石英砂过150目筛，然后进行水洗，自然风干。
(2)称取原料如下：工业氧化铝8.8g、铝矾土4.4g、海南石英砂2.6g、氧化锆0.4g、碳化硅1.58g、钾长石1g、滑石1g、氧化镁0.2g、羧甲基纤维素钠(CMC)0.02g。
(3)将所有原料按料:氧化锆球:水＝1:2:1的质量比置于球磨机中进行球磨12小时，放浆时通过300目筛进行筛分，得到混合浆料。并用磁铁棒进行除铁处理。
(4)将混合浆料通过喷雾干燥得到具有一定流动性的混合粉体。
(5)将混合粉体装入橡胶模具，采用冷等静压工艺将粉料压制成型，成型压力为140MPa，保压5分钟。
(6)将成型的陶瓷坯体放置在高温马弗炉中，室温至700℃以5℃/分钟升温，然后以10℃/分钟升温至1550℃，保温1小时，试样随炉自然降温得到增韧陶瓷材料。
(7)任选地，将烧结后的材料进行磨抛处理，得到试样成品用于测试。
实施例4托辊用陶瓷材料的制备
实施例4与实施例1的区别在于步骤(2)称取原料如下：工业氧化铝8.2g、铝矾土4.7g、海南石英砂2.9g、氧化锆0.42g、碳化硅1.5g、钾长石1.0g、滑石1.0g、氧化镁0.25g、羧甲基纤维素钠(CMC)0.03g。
实施例5托辊用陶瓷材料的制备
实施例5与实施例1的区别在于步骤(2)称取原料如下：工业氧化铝9.4g、铝矾土4.3g、海南石英砂2.5g、氧化锆0.34g、碳化硅1.4g、钾长石0.92g、滑石0.92g、氧化镁0.2g、羧甲基纤维素钠(CMC)0.02g。
表征
以实施例1制备的增韧陶瓷材料为例，对实施例1制备的增韧陶瓷材料的断面进行扫描电镜表征(日立高新S-4800冷场发射扫描电子显微镜)，结果如图1所示；
从图1中可以看出本发明制备的增韧陶瓷材料中，原位生成了莫来石的短晶须(见箭头1)，同时有柱状晶氧化锆(见箭头2)形成，氧化锆发生相变对基体起增韧作用。此外，碳化硅微粒(箭头3)均匀分散在陶瓷基体中，也可发挥增强的作用；发生断裂时，碳化硅颗粒的拔出效应对陶瓷又起到很好的增韧效果。由此可见，本发明实现了通过氧化锆、碳化硅颗粒、原位形成莫来石晶须三者的协同增韧作用提高陶瓷的断裂韧性的目的。
性能测试
测试实施例1-5制备的增韧陶瓷材料的相对密度、吸水率、弯曲强度、断裂韧性，测试结果见表1。
测试方法
(1)相对密度:试样的相对密度是用试样的体积密度除以试样的理论密度，试样的理论密度根据原料配比和各原料自身的理论密度即可计算出来，体积密度用阿基米德法测定，计算公式为：
其中：m1为试样完全干燥后在空气中的质量，m2为试样用水煮沸3h,然后冷却至室温，静放24h后，悬浮于水中的质量，m3为将试样从水中取出，用干净绵纸轻轻将试样表面的水擦去，在空气中的质量；ρw为水在室温(25℃)下的密度(0.9970g/cm3)。
(2)吸水率：依照GB/T 3299-2011日用陶瓷器吸水率测定方法。
(3)弯曲强度：采用三点弯曲法，具体依照GB/T 6569-2006精细陶瓷弯曲强度试验方法。
(4)断裂韧性:依照国标(SEPB法)GB/T 23806-2009进行。
表1
| 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | |
| 相对密度/％ | 93.7 | 95.8 | 96.5 | 92.8 | 93.4 |
| 吸水率/％ | 1.2 | 0.9 | 0.37 | 1.5 | 1.3 |
| 弯曲强度/MPa | 589 | 601 | 629 | 558 | 571 |
| 断裂韧性/MPa·m1/2 | 6.4 | 6.8 | 7.1 | 6.1 | 5.7 |
由上表1可以看出，与普通未增韧的陶瓷托辊的断裂韧性不超过5.0MPa·m1/2相比，由本发明的方法制备的经增韧的托辊用陶瓷材料的断裂韧性显著提高，不仅如此，由本发明的方法制备的经增韧的托辊用陶瓷材料还具有较高的相对密度、弯曲强度及较低的吸水率，更适于用作陶瓷托辊。
以上对本发明所提供的一种托辊用陶瓷材料及其制备方法进行了详细介绍。本文中应用了具体实施例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其中心思想。应当指出，对于本领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以对本发明进行若干改进和修饰，这些改进和修饰也落入本发明权利要求的保护。
Claims (10)
1.一种托辊用陶瓷材料的制备方法，其特征在于，包括：
(1)称取原料，基于所述原料的总质量，所述原料包括以质量分数计的如下组分：氧化铝41-47％、铝矾土21.5-23.5％、石英砂12.5-14.5％、氧化锆1.7-2.1％、碳化硅7.0-7.5％、钾长石4.6-5.0％、滑石4.6-5.0％、氧化镁1.0-1.25％、羧甲基纤维素钠0.1-0.15％；
(2)将所述原料进行湿法球磨，球磨结束后干燥处理，得到混合粉体；
(3)将所述混合粉体装入模具后采用冷等静压工艺压制成型，得到陶瓷坯体；
(4)将所述陶瓷坯体于1450-1550℃烧结0.5-3小时。
2.如权利要求1所述的方法，其特征在于，步骤(1)中，所述石英砂经过以下预处理：过100-200目筛，然后进行水洗，风干。
3.如权利要求1所述的方法，其特征在于，步骤(2)中的湿法球磨包括：将所述原料、研磨介质、分散介质置于球磨机中进行球磨12-15小时，然后过200-400目筛。
4.如权利要求3所述的方法，其特征在于，所述原料、研磨介质、分散介质的质量比例为1:2:1；优选地，所述研磨介质为氧化锆球；所述分散介质为水。
5.如权利要求1所述的方法，其特征在于，在步骤(2)球磨结束后，对球磨得到的混合浆料用磁铁进行除铁处理。
6.如权利要求1所述的方法，其特征在于，在步骤(2)中采用喷雾干燥的方式进行干燥处理。
7.如权利要求1所述的方法，其特征在于，步骤(3)中的冷等静压工艺参数包括：成型压力140-160MPa；保压3-5分钟。
8.如权利要求1所述的方法，其特征在于，步骤(3)中烧结的升温速率为：以5℃/分钟的升温速率升温至700℃，再以10℃/分钟的升温速率升温至1450-1550℃。
9.如权利要求1-8中任一项所述的方法，其特征在于，所述石英砂为海南石英砂。
10.权利要求1-9中任一项所述的方法制备的托辊用陶瓷材料。
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