CN108484136B - 一种高耐磨滑板砖及其生产方法 - Google Patents
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Abstract
本发明公开了一种高耐磨滑板砖，按重量百分比计，原料组成为：铝粉包覆板状刚玉颗粒60～70%，板状刚玉粉15～25%，氧化铝微粉5～10%，铝粉3～9%，硅粉1～3%，炭黑1～3%，石墨1～3%，酚醛树脂2～5%。制备方法如下：按比例称取各组分，经湿碾机混练0.5小时后困料6～8小时，在压力机上成型，坯体在160～180℃温度条件下干燥24h，然后放入炉内，在弱还原气氛下进行650～800℃×12h的中温处理，处理后的坯体经套箍、粘钢壳、磨制、涂布、精整、验收后入库贮存。本发明生产的高耐磨Al2O3‑Al‑C滑板砖具有较高的热态强度、良好的抗热震性和抗氧化性，可减少滑动面磨损夹钢现象，降低冲刷扩孔速度，提高滑板的使用寿命，降低吨钢滑动水口耐火材料消耗。
Description
技术领域
本发明涉及一种炼钢连铸用滑板砖，特别涉及一种高耐磨滑板砖及其生产方法，属于铝碳系列滑板砖生产领域。
背景技术
滑板砖用于钢铁工业连铸工艺，起调节和控制钢水流量的作用，或用于炼钢炉的挡渣出钢系统上。滑板在使用时高温钢水冲刷及滑动面磨损是其主要损毁原因，因此，提高滑板的高温强度是增加其抗冲刷磨损性、增加使用寿命的主要措施。
目前高温烧成Al2O3-C质、Al2O3-ZrO2-C质及中温处理或不烧的Al2O3-Al-C质、Al2O3-Al-ZrO2-C质是滑板砖的主要材质，其提高滑板高温强度的主要措施一是通过添加微粉促进高温烧结，形成陶瓷结合相；二是添加Si粉、Al粉，高温时形成非氧化物结合相。从滑板内部物料组成看，由颗粒和基质组成，基质中的微粉及Si粉、Al粉通过高温形成陶瓷结合及非氧化物结合，将基质中各种粉料结合起来，使基质具有较高的高温强度。颗粒一般选用高温烧结板状刚玉、电熔白刚玉、电熔锆莫来石或锆刚玉、高温烧结矾土熟料等致密原料，使颗粒也具有较高的高温强度。但基质和颗粒之间难以形成较好的结合，造成两者界面间呈弱结合状态，从颗粒到基质微区的强度呈“V”型分布，影响滑板的高温强度。使用时经高温冲刷磨损，颗粒容易从基体中脱落，造成扩孔较大、滑动面拉毛严重，影响其使用寿命的提高。因此，必须采用新的技术措施，提高滑板中颗粒与基质间的结合强度，关于此方面的技术，还没有相关的研究报道。
发明内容
本发明所要解决的技术问题是：针对铝碳滑板中颗粒与基质间结合强度低、不耐冲刷磨损、造成扩孔拉毛、影响使用寿命提高的技术问题，提供一种高耐磨滑板砖及其生产方法，通过添加铝粉包覆板状刚玉颗粒，在高温下包覆的铝粉在板状刚玉颗粒表面原位生成纤维状或针状、呈放射状分布的Al4C3、AlN等非氧化物，使颗粒成为类“链球结构”，建立颗粒与基质间的桥接，增加对颗粒的把持力，强化其界面结合，达到提高滑板高温强度及高温耐磨性，增加使用寿命的目的。
本发明为解决技术问题所采取的技术方案是：
一种高耐磨滑板砖，按重量百分比计，该滑板砖的原料组成为：铝粉包覆板状刚玉颗粒60～70%，板状刚玉粉15～25%，氧化铝微粉5～10%，铝粉3～9%，硅粉1～3%，炭黑1～3%，石墨1～3%，酚醛树脂2～5%。
上面所述的添加铝粉包覆板状刚玉颗粒的滑板砖的制备方法，其具体步骤如下：
A、铝粉包覆板状刚玉颗粒的制备：
a、先将各种粒度的板状刚玉颗粒加入搅拌机中搅拌3～5分钟，得混合料A；
b、搅拌均匀后加入混合料A重量份2～4%的结合剂继续搅拌5～8分钟得混合料B，结合剂为树脂粉与乙醇的混合液，二者的重量比为2∶3～3∶2；
c、搅拌均匀后再缓慢加入325目的铝粉继续搅拌5～8分钟得混合料C，铝粉的加入量为混合料B重量份的4～8%；
d、混合料C自然干燥4～6h后，在80℃下烘干4h，经150℃烘干3～4小时后，制得具有较高结合强度的铝粉包覆板状刚玉颗粒；
B、按重量百分比称量以下各组分投入湿碾机中进行混练：铝粉包覆板状刚玉颗粒60～70%，板状刚玉粉15～25%，氧化铝微粉5～10%，铝粉3～9%，硅粉1～3%，炭黑1～3%，石墨1～3%，酚醛树脂2～5%；
C、经湿碾机混练0.5小时后困料6～8小时，根据滑板单重、形状选择在不同吨位的压力机上成型；
D、成型的坯体在160～180℃温度条件下干燥24h，然后放入炉内，在弱还原气氛下进行650～800℃×12h的中温处理；
E、中温处理后的坯体经套箍、粘钢壳、磨制、涂布、精整、验收后入库贮存。
所述板状刚玉颗粒的组成为：粒径为1～3mm的板状刚玉颗粒占40～60%，粒径为0.44～1mm的板状刚玉颗粒占10～30%。
所述弱还原气氛为在隔绝空气下加热。
本发明的积极有益效果如下：
1、本发明通过用酚醛树脂与乙醇的混合液做结合剂，加入4～8%的325目铝粉，搅拌均匀后出料，包覆颗粒自然干燥4h后进行80℃×4h及150℃×4h烘干，制得具有较高结合强度的铝粉包覆板状刚玉颗粒。高温还原气氛下包覆的铝粉在刚玉颗粒表面原位生成纤维状或针状、呈放射状分布的Al4C3、AlN等非氧化物，在材料内形成类“链球结构”，强化了颗粒与基质间的结合，对材料起增强增韧作用，提高了界面的结合强度，提高了材料的高温抗折强度，改善了抗热震性和高温耐磨性。
2、本发明制备生产的高耐磨Al2O3-Al-C滑板砖具有较高的热态强度、良好的抗热震性和抗氧化性，先后成功地应用于100-220吨大中型钢包上，结果表明：高耐磨滑板滑程拉毛程度明显降低，可减少滑动面夹钢现象，降低了扩孔速度，提高了滑板的使用寿命，降低了吨钢滑动水口耐火材料的消耗，取得了显著的经济效益。
3.材料显微结构分析表明：
颗粒与基质结合紧密，颗粒表面铝粉包覆层的轮廓清晰，其厚度约0.03～0.10mm。颗粒表面部分包覆铝粉融化后向周围基质中扩散，与细粉融合在一起。在铝液表面张力的作用下，将周围颗粒拉紧，使材料致密化，强度增加。
高温时包覆铝粉在板状刚玉颗粒表面原位生成AlN和Al4C3非氧化物，由于表面生成大量的非氧化物，使颗粒成为类“链球结构”，链的一端生长在颗粒表面，另一端与基质相连，强化了颗粒界面，提高了颗粒与基质间的结合强度，增加了断裂能，同时颗粒表面生成大量的非氧化物，使材料的高温抗折强度大幅度提高。当颗粒被磨损或冲刷时将消耗更多的能量，增加其高温耐磨性，有助于提高滑板表面及铸孔的抗冲刷磨损性。
随着材料高温强度的提高，增加了裂纹成核壁垒，有利于改善其抗热震性。若因热应力作用在材料内产生了裂纹，当裂纹扩展到颗粒表面时，由于类“链球结构”的存在，形成桥联机制、偏转机制和拔出效应，增加裂纹扩展的能耗，对材料起增韧作用，提高其抗热震性。所以采用本专利生产的滑板，用后残砖的裂纹明显减少。
4、本发明开发的颗粒界面强化技术还可用于高炉用Al2O3-C砖、鱼雷罐用Al2O3-SiC-C砖、连铸三大件用的Al2O3-ZrO2-C制品等碳复合耐火材料，提高它们的高温力学性能。
本发明高耐磨Al2O3-Al-C滑板的理化指标：
目高耐磨Al2O3-Al-C滑板分为HBLT-85N、HBLTG-82N两个牌号，后者含有适量的氧化锆，适于钙处理钢的浇注，产品理化指标的典型值见下表：
具体实施方式：
下面对本发明做进一步的解释和说明：
实施例：一种高耐磨滑板砖，按重量百分比计，该滑板砖的原料组成为：铝粉包覆板状刚玉颗粒60～70%，板状刚玉粉15～25%，氧化铝微粉5～10%，铝粉3～9%，硅粉1～3%，炭黑1～3%，石墨1～3%，酚醛树脂2～5%。
上面所述的高耐磨滑板砖的制备方法，其具体步骤如下：
A、铝粉包覆板状刚玉颗粒的制备：
a、先将各种粒度的板状刚玉颗粒加入搅拌机中搅拌3～5分钟，得混合料A；
b、搅拌均匀后加入混合料A重量份2～4%的结合剂继续搅拌5～8分钟得混合料B，结合剂为树脂粉与乙醇的混合液，二者的重量比为2∶3～3∶2；
c、搅拌均匀后再缓慢加入325目的铝粉继续搅拌5～8分钟得混合料C，铝粉的加入量为混合料B重量份的4～8%；
d、混合料C自然干燥4～6h后，在80℃下烘干4h，经150℃烘干3～4小时后，制得具有较高结合强度的铝粉包覆板状刚玉颗粒；
B、按重量百分比称量以下各组分投入湿碾机中进行混练：铝粉包覆板状刚玉颗粒60～70%，板状刚玉粉15～25%，氧化铝微粉5～10%，铝粉3～9%，硅粉1～3%，炭黑1～3%，石墨1～3%，酚醛树脂2～5%；
C、经湿碾机混练0.5小时后困料6～8小时，根据滑板单重、形状选择在不同吨位的压力机上成型；
D、成型的坯体在160～180℃温度条件下干燥24h，然后放入炉内，在弱还原气氛下进行650～800℃×12h的中温处理；
E、中温处理后的坯体经套箍、粘钢壳、磨制、涂布、精整、验收后入库贮存。
所述板状刚玉颗粒的组成为：粒径为1～3mm的板状刚玉颗粒占50～70%，粒径为0.44～1mm的板状刚玉颗粒占30～50%。
本发明制备生产的高耐磨Al2O3-Al-C滑板砖具有较高的热态强度、良好的抗热震性和抗氧化性，高耐磨滑板滑程拉毛程度明显降低，可减少滑动面夹钢现象，降低扩孔速度，提高滑板的使用寿命，降低吨钢滑动水口耐火材料的消耗。本发明还可用于高炉用Al2O3-C砖、鱼雷罐用Al2O3-SiC-C砖、连铸三大件用的Al2O3-ZrO2-C制品等碳复合耐火材料，提高它们的高温性能。
Claims (4)
1.一种高耐磨滑板砖，其特征在于，按重量百分比计，该滑板砖的原料组成为：铝粉包覆板状刚玉颗粒60～70%，板状刚玉粉15～25%，氧化铝微粉5～10%，铝粉3～9%，硅粉1～3%，炭黑1～3%，石墨1～3%，酚醛树脂2～5%。
2.权利要求1所述的高耐磨滑板砖的制备方法，其具体步骤如下：
A、铝粉包覆板状刚玉颗粒的制备：
a、先将各种粒度的板状刚玉颗粒加入搅拌机中搅拌3～5分钟，得混合料A；
b、搅拌均匀后加入混合料A重量份2～4%的结合剂继续搅拌5～8分钟得混合料B，结合剂为树脂粉与乙醇的混合液，二者的重量比为2∶3～3∶2；
c、搅拌均匀后再缓慢加入325目的铝粉继续搅拌5～8分钟得混合料C，铝粉的加入量为混合料B重量份的4～8%；
d、混合料C自然干燥4～6h后，在80℃下烘干4h，经150℃烘干3～4小时后，制得具有较高结合强度的铝粉包覆板状刚玉颗粒；
B、按重量百分比称量以下各组分投入湿碾机中进行混练：铝粉包覆板状刚玉颗粒60～70%，板状刚玉粉15～25%，氧化铝微粉5～10%，铝粉3～9%，硅粉1～3%，炭黑1～3%，石墨1～3%，酚醛树脂2～5%；
C、经湿碾机混练0.5小时后困料6～8小时，根据滑板单重、形状选择在不同吨位的压力机上成型；
D、成型的坯体在160～180℃温度条件下干燥24h，然后放入炉内，在弱还原气氛下进行650～800℃×12h的中温处理；
E、中温处理后的坯体经套箍、粘钢壳、磨制、涂布、精整、验收后入库贮存。
3.根据权利要求2所述的高耐磨滑板砖的制备方法，其特征在于，所述板状刚玉颗粒的组成为：粒径为1～3mm的板状刚玉颗粒占40～60%，粒径为0.44～1mm的板状刚玉颗粒占10～30%。
4.根据权利要求2所述的高耐磨滑板砖的制备方法，其特征在于，所述弱还原气氛为在隔绝空气下加热。
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