CN108794017A - 一种耐磨陶瓷复合管的制备方法 - Google Patents

一种耐磨陶瓷复合管的制备方法 Download PDF

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CN108794017A
CN108794017A CN201810643588.0A CN201810643588A CN108794017A CN 108794017 A CN108794017 A CN 108794017A CN 201810643588 A CN201810643588 A CN 201810643588A CN 108794017 A CN108794017 A CN 108794017A
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张轶
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Hubei Qinhong New Material Co ltd
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Abstract

本发明属于耐磨材料技术领域，特别涉及一种耐磨陶瓷复合管的制备方法，包括以下步骤：S1，按质量份计，称取碳化硅陶瓷颗粒40～50份，氮化硅陶瓷颗粒50～60份，亚微米级氮化钛5～12份，和粘结剂4～8份，放入容器中混合均匀后得到混合物料；S2，将所述混合物料倒入模具中成型，制得预制件；S3，将预制件烧结，再经淬火、回火步骤后制得多孔陶瓷基体；S4，将多孔陶瓷基体放入浇模中，将金属材料熔化后对多孔陶瓷基体浇注，冷却后形成耐磨陶瓷复合管。本发明能够将金属的韧性、抗弯型，与陶瓷的高耐磨、高强度和抗氧化性能有机结合，制得的耐磨陶瓷复合管整体的强度、抗冲击韧性和耐磨性均有极大地提高。

Description

一种耐磨陶瓷复合管的制备方法
技术领域
本发明属于耐磨材料技术领域，特别涉及一种耐磨陶瓷复合管的制备方法。
背景技术
耐磨材料广泛应用于火电、钢铁、冶炼、机械、煤炭、矿山、化工、水泥、港口码头等企业的输煤、输料系统、制粉系统、排灰、除尘系统等一切磨损大的机械设备上，比如在物料(铁矿石、煤炭等)装卸机械料斗系统中使用，具体部位在导料板、落料回收版、斗轮回弧耐磨板等易磨损部位。耐磨陶瓷复合管在烧结时，金属与陶瓷颗粒不能充分的混匀，导致耐磨陶瓷复合管的金属相和陶瓷相分布不均，导致耐磨性产生较大差异。
CN205842096U公开了一种复合型耐高温耐磨损烟气输送管道，其采用机械结构将耐磨陶瓷与金属固定在一起。CN107339519A公开了一种新型耐磨耐蚀复合管道及其制备方法，其通过粘接的方式将耐磨陶瓷与金属固定在一起。现有的操作工艺不能够很好的将耐磨陶瓷与金属有机地结合，使用寿命较短。
CN202461486U的中国专利公开了一种金属陶瓷增强体，在增强体上下两个端面上设有多个通孔，并设有安装槽，使用时将通过相互配合的安装槽将多个增强体拼接后形成整体，然后在通孔中浇注钢水，冷却后得到产品，从而完整的将易磨损部位保护起来。然而，该申请的金属陶瓷增强体内部致密，钢水在浇注时不能够有效渗透到增强体的内部，而实际起到耐磨损作用的是碳化硅陶瓷，导致耐磨产品的使用效果较差。
发明内容
本发明为了解决上述问题，提供一种耐磨陶瓷复合管的制备方法，能够将金属的韧性、抗弯型，与陶瓷的高耐磨、高强度和抗氧化性能有机结合，制得的耐磨陶瓷复合管整体的强度、抗冲击韧性和耐磨性均有极大地提高。
本发明采用以下技术方案来实现：
一种耐磨陶瓷复合管的制备方法，包括以下步骤：
S1，按质量份计，称取碳化硅陶瓷颗粒40～50份，氮化硅陶瓷颗粒50～60份，亚微米级氮化钛5～12份，和粘结剂4～8份，放入容器中混合均匀后得到混合物料；
S2，将所述混合物料倒入模具中成型，制得具有通孔的预制件；
S3，将预制件放入气氛炉内，在1100～1300℃条件下烧结30～50min，再经淬火、回火步骤后制得多孔陶瓷基体；
S4，将多孔陶瓷基体放入浇模中，将金属材料熔化后对多孔陶瓷基体浇注，冷却后形成耐磨陶瓷复合管。
优选的方案，在步骤S2中，所述通孔的直径为0.4～0.8mm。设置较小的通孔直径有助于浇注的金属材料迅速凝固，降低了制造难度。
优选的方案，在步骤S4中，先将多孔陶瓷基体进行抛光处理，然后放入浇模中。抛光处理使第一多孔陶瓷板和第二多孔陶瓷板之间形成光面连接，保证了第一浇注通孔和第二浇注通孔之间形成良好的连通效果，并保证金属基体的形状结构与设计相符。
优选的方案，在步骤S4中，所述金属材料从多孔陶瓷基体的外部向内浇注而成。
优选的方案，在步骤S4中，所述金属材料采用负压进行浇注。本发明与常规浇注方式不同的是，采用负压金属材料从多孔陶瓷基体的外部向内浇注，使得金属材料能够充满浇注通孔，使多孔陶瓷基体与金属材料实现无缝接合；另外，浇注时，熔化的金属材料首先接触多孔陶瓷基体的外侧(即非主要起耐磨效果的部位)，熔化的金属材料首先腐蚀多孔陶瓷基体的外侧，最后接触多孔陶瓷基体的内侧(即主要起耐磨效果的部位)，制得的耐磨陶瓷复合管的内侧中金属材料占比较小，提高了耐磨陶瓷复合管的使用寿命，尤其适用于管道等具有特殊形状的耐磨复合材料的制作。
优选的方案，所述负压为0.02～0.05MPa。通孔为直径0.4～1mm的毛细孔，金属材料由多孔陶瓷基体的外部向内浇注时，在直径为0.4～1mm的通孔内形成曲面，能够促进金属材料迅速充满通孔，在较小的负压条件下即可实现较好的浇注效果，无需对现有设备进行改造即可完成浇注过程。
优选的方案，所述碳化硅陶瓷颗粒的密度为3.2～3.25g/cm3，且，所述氮化硅陶瓷颗粒和密度为3.12～3.2g/cm3。在步骤S1中，原料中碳化硅陶瓷颗粒40～50份，氮化硅陶瓷颗粒50～60份，二者作为主要原料，在混合时无需担心分层现象，制得的混合物料各物质成分分布混匀，适合批量生产，对产品质量的把控较好。
优选的方案，所述碳化硅颗粒平均粒径0.1mm，所述氮化硅平均粒径500um，所述亚微米级氮化钛平均粒径600nm。较大粒径的碳化硅颗粒作为主要原材料，其使用温度达1380℃，价格较低，但不耐融化的金属材料腐蚀，其反应机理主要在于，高温状态下，碳化硅与铁氧化物可发生如下：SiC(s)+3FeO(l)＝SiO2(s)+CO(g)+3Fe(l)及其类似反应，导致碳化硅颗粒被腐蚀。氮化硅颗粒的使用温度1200℃，在1200℃以上会随使用时间的增长而出现破损，使其强度降低，在1450℃以上更易出现疲劳损坏，但是能够耐融化的金属材料腐蚀，其价格比碳化硅颗粒价格高；而氮化钛具有优良的耐高温性能和耐熔融金属材料的腐蚀性能卓越，但是价格更高。较大粒径的碳化硅颗粒表面被碳化硅、氮化钛颗粒包覆形成耐腐蚀保护层，使本发明的耐磨陶瓷复合管具有优良的耐磨性，使用寿命大大提高。
氮化钛在高温下不与铁、铬、钙和镁等金属反应，抗熔融金属侵蚀的性能卓越。
本发明的有益效果是：
1、本发明的耐磨陶瓷复合管将金属的韧性、抗弯型，与陶瓷的高耐磨、高强度和抗氧化性能有机结合，整体的强度、抗冲击韧性和耐磨性均有极大地提高。
2、本发明选用密度为3.2～3.25g/cm3的氮化硅陶瓷颗粒和密度为3.12～3.2g/cm3的氮化硅陶瓷颗粒作为陶瓷基料，不仅减少了高温熔融金属材料在浇注时高温熔融金属材料对碳化硅的吸收作用，且，碳化硅和氮化硅的比重近似，混合时无需担心分层现象。
3、在相同的尺寸条件下，圆形具有最大的接触面积，提高了金属基体对多孔陶瓷基体的补强作用，金属基体与多孔陶瓷基体的接触面为弧形，避免了金属基体与多孔陶瓷基体在长时间的冲击下产生分离，而保证了连接的紧密性，二者设置的特殊的位置关系，提高了多孔陶瓷基体与金属基体之间相互协同的补强作用。
4、本发明较大粒径的碳化硅颗粒表面被氮化硅、氮化钛颗粒包覆形成耐腐蚀保护层，利用氮化硅和氮化钛能耐铁、铝等金属及合金的溶蚀性能，减少了浇注时对碳化硅材料的腐蚀作用，使本发明的耐磨陶瓷复合管具有优良的耐磨性，使用寿命大大提高。
5、本发明采用负压金属材料从多孔陶瓷基体的外部向内浇注，熔化的金属材料首先接触多孔陶瓷基体的外侧，最后接触多孔陶瓷基体的内侧，能够减少在浇注过程中熔化的金属材料对多孔陶瓷基体的腐蚀作用，制得的耐磨陶瓷复合管的内侧中金属材料占比较小，提高了耐磨陶瓷复合管的使用寿命，尤其适用于管道等具有特殊形状的耐磨复合材料的制作。
6、本发明的浇注压力为0.02～0.05Mpa，通孔为直径0.4～0.8mm的毛细孔，金属材料由多孔陶瓷基体的外部向内浇注时，在直径为0.4～0.8mm的通孔内形成曲面，能够促进金属材料迅速充满通孔，在较小的负压条件下即可实现较好的浇注效果，无需对现有设备进行改造即可完成浇注过程。
7、本发明的金属材料为高铬铸铁材料，高铬铸铁是高铬白口抗磨铸铁的简称，是一种性能优良而受到特别重视的抗磨材料，比合金钢的耐磨性高很多，且具有一般白口铸铁所不具备的高韧性、高强度，还兼有良好的抗高温和抗腐蚀性能，生产便捷、成本适中。
具体实施方式
下面对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的一部分实施例，而不是全部的实施例。基于本发明的实施例，本领域一般技术人员在没有作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。
实施例1
一种耐磨陶瓷复合管的制备方法，包括以下步骤：
S1，按质量份计，称取密度为3.23g/cm3、平均粒径0.1mm的碳化硅陶瓷颗粒45份，密度为3.16g/cm3、平均粒径500um的氮化硅陶瓷颗粒55份，平均粒径600nm的亚微米级氮化钛8份，和环氧树脂6份，放入容器中混合均匀后得到混合物料；
S2，将所述混合物料倒入模具中成型，制得具有0.6mm通孔的预制件；
S3，将预制件放入气氛炉内，在1200℃条件下烧结450min，再经淬火、回火步骤后制得多孔陶瓷基体；
S4，将多孔陶瓷基体进行抛光处理，然后放入浇模中，将高铬铸铁材料熔化后，在0.04MPa的负压环境下从多孔陶瓷基体的外部向内浇注，冷却后形成耐磨陶瓷复合管。
实施例2
一种耐磨陶瓷复合管的制备方法，包括以下步骤：
S1，按质量份计，称取密度为3.25g/cm3、平均粒径0.1mm的碳化硅陶瓷颗粒50份，密度为3.12g/cm3、平均粒径500um的氮化硅陶瓷颗粒50份，平均粒径600nm的亚微米级氮化钛5份和酚醛液体树脂4份，放入容器中混合均匀后得到混合物料；
S2，将所述混合物料倒入模具中成型，制得具有0.4mm通孔的预制件；
S3，将预制件放入气氛炉内，在1100℃条件下烧结50min，再经淬火、回火步骤后制得多孔陶瓷基体；
S4，将多孔陶瓷基体进行抛光处理，然后放入浇模中，将高铬铸铁材料熔化后，在0.02MPa的负压环境下从多孔陶瓷基体的外部向内浇注，冷却后形成耐磨陶瓷复合管。
实施例3
一种耐磨陶瓷复合管的制备方法，包括以下步骤：
S1，按质量份计，称取密度为3.2g/cm3、平均粒径0.1mm的碳化硅陶瓷颗粒40份，密度为3.2g/cm3、平均粒径500um的氮化硅陶瓷颗粒60份，平均粒径600nm的亚微米级氮化钛12份，和聚氯乙烯8份，放入容器中混合均匀后得到混合物料；
S2，将所述混合物料倒入模具中成型，制得具有0.8mm通孔的预制件；
S3，将预制件放入气氛炉内，在1300℃条件下烧结30min，再经淬火、回火步骤后制得多孔陶瓷基体；
S4，将多孔陶瓷基体进行抛光处理，然后放入浇模中，将高铬铸铁材料熔化后，在0.05MPa的负压环境下从多孔陶瓷基体的外部向内浇注，冷却后形成耐磨陶瓷复合管。
以申请号为201220097663.6，授权公告号为CN202461486U的中国专利中公开的金属陶瓷增强体采用与实施例1～3所用高铬铸铁材料制备的耐磨材料作为对比样品，以本发明实施例1～3制备的耐磨陶瓷复合管作为实施样品1～3，分别采用将对比样品和实施样品1～3放在MMH-5环块三体磨损试验机上进行对比磨损试验，磨料为石英砂，主轴转速30rpm，载荷用砝码加载方式，单轴试验力3kg，每磨2小时对两种不同试样进行清洗干燥称重计算，通过对比，实施样品1～3在MMH-5环块三体磨损试验机上磨损性能分别是对比样品的1.68倍、1.72倍和1.66倍。

Claims (8)

1.一种耐磨陶瓷复合管的制备方法，其特征在于，包括以下步骤：
S1，按质量份计，称取碳化硅陶瓷颗粒40～50份，氮化硅陶瓷颗粒50～60份，亚微米级氮化钛5～12份，和粘结剂4～8份，放入容器中混合均匀后得到混合物料；
S2，将所述混合物料倒入模具中成型，制得具有通孔的预制件；
S3，将预制件放入气氛炉内，在1100～1300℃条件下烧结30～50min，再经淬火、回火步骤后制得多孔陶瓷基体；
S4，将多孔陶瓷基体放入浇模中，将金属材料熔化后对多孔陶瓷基体浇注，冷却后形成耐磨陶瓷复合管。
2.根据权利要求1所述耐磨陶瓷复合管的制备方法，其特征在于，在步骤S2中，所述通孔的直径为0.4～0.8mm。
3.根据权利要求1所述耐磨陶瓷复合管的制备方法，其特征在于，在步骤S4中，先将多孔陶瓷基体进行抛光处理，然后放入浇模中。
4.根据权利要求1所述耐磨陶瓷复合管的制备方法，其特征在于，在步骤S4中，所述金属材料从多孔陶瓷基体的外部向内浇注而成。
5.根据权利要求4所述耐磨陶瓷复合管的制备方法，其特征在于，在步骤S4中，所述金属材料采用负压进行浇注。
6.根据权利要求5所述耐磨陶瓷复合管的制备方法，其特征在于：所述负压为0.02～0.05MPa。
7.根据权利要求1所述耐磨陶瓷复合管的制备方法，其特征在于，所述碳化硅陶瓷颗粒的密度为3.2～3.25g/cm3，且，所述氮化硅陶瓷颗粒和密度为3.12～3.2g/cm3。
8.根据权利要求1所述耐磨陶瓷复合管的制备方法，其特征在于，所述碳化硅颗粒平均粒径0.1mm，所述氮化硅平均粒径500um，所述亚微米级氮化钛平均粒径600nm。
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