CN109133958B - 一种原位定向非氧化物增强碳化硅砖及其制备方法 - Google Patents

一种原位定向非氧化物增强碳化硅砖及其制备方法 Download PDF

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CN109133958B
CN109133958B CN201810981491.0A CN201810981491A CN109133958B CN 109133958 B CN109133958 B CN 109133958B CN 201810981491 A CN201810981491 A CN 201810981491A CN 109133958 B CN109133958 B CN 109133958B
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李纪伟
邵淑英
贾博
侯春玲
毕振勇
陈鱼军
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Henan Higer Refractories Co ltd
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Abstract

本发明公开了一种成本低廉、工艺简单、氮化反应更充分、冷热态强度更高、韧性更好且使用寿命显著提高的一种原位定向非氧化物增强碳化硅砖及其制备方法。主料包括碳化硅骨料和粉料、金属硅、氧化铝微粉、二氧化硅微粉，本发明在创新地现有碳化硅砖工艺基础上，引进有机纤维，有机纤维在低温（低于200度）下可被融化或烧失而留下纤维状空间，高温氮气环境下，Si和N2以气相方式优先在该纤维空间内形成非氧化结合相并获得更好的发育程度，从而在砖体内部形成呈纤维状弥散穿插分布的簇状非氧化物相，从而提高碳化硅砖的强度和韧性。

Description

一种原位定向非氧化物增强碳化硅砖及其制备方法
技术领域
本发明涉及一种碳化硅砖，尤其涉及一种原位定向非氧化物增强碳化硅砖及其制备方法。
背景技术
碳化硅砖是以碳化硅骨料及细粉为主要原料，选择合适结合方式，通过机压或浇注成形，再经烘烤和高温烧成之后获得的高档耐火材料，具有化学稳定性好、热导率高、冷热态强度高、耐磨性好等优点，广泛应用于钢铁、有色冶金、石化等行业的高温窑炉内衬上。
碳化硅（SiC）砖按照结合方式分为氧化物结合和非氧化物结合两大类。非氧化物结合根据具体结合物相, 又可分为氮化硅（Si3N4）结合、氧氮化硅（Si2N2O）结合和塞隆（Sialon）结合。
碳化硅砖的原料主要为碳化硅、金属硅以及SiO2、Al2O3（视品种选择）等少量添加组分，常用结合剂为木质素磺酸钙、糊精或树脂。采用压制成型和高温氮化烧成。在氮化烧成中，金属硅与氮气（N2）通过气相反应生成Si3N4以及Si2N2O、Sialon等非氧化物结合相，从而产生极好的冷、热态强度。
非氧化物结合碳化硅砖在生产过程中，氮化程度受制品形状尤其是厚度的影响很大，因为与氮气的反应总是自砖体表面开始，逐步向里，当砖体过厚时，表层氮化程度较高,而内部氮化程度低，使得内外成分及强度均有差异。加之碳化硅砖在使用中需经受频繁的冷热循环以及极高的温度梯度，使其常因砖体内部热应力过大而损毁。鉴于此，如何提高和促进碳化硅砖在氮化烧成中的氮化程度和效率并进一步提高碳化硅砖的冷热态强度是非氧化物结合碳化硅砖的研究重点之一。
发明内容
本发明的目的是为了解决上述技术问题存在的不足，提供一种成本低廉、工艺简单、氮化反应更充分、冷热态强度更高、韧性更好且使用寿命显著提高的一种原位定向非氧化物增强碳化硅砖及其制备方法。
本发明包括主料、防氧化剂和结合剂，主料包括碳化硅骨料和粉料、金属硅、氧化铝微粉、二氧化硅微粉，加入重量份数为：碳化硅骨料和粉料70-85份，金属硅10-25份，氧化铝微粉0-3份, 二氧化硅微粉0-5份; 防氧化剂加入量是主料总重量的0-2%，结合剂加入量是主料总重量的2-5%，有机纤维加入量是主料总重量的0.1-0.5%。
其中防氧化剂、结合剂和有机纤维均为外加形式加入。
其中有机纤维为防爆纤维，可在200度下融化从而形成微细气孔。
其中有机纤维直径20~40μm，长度3~5mm。引入有机纤维的目的在于通过其在一定温度下融化产生若干个空隙，这些空隙有利于氮化反应中为窑内氮气提供进入砖体内部的通道，不仅提高和促进碳化硅砖在氮化烧成中的氮化程度和效率, 减小或消除砖体表面和内部的氮化反应程度差异，综合提高最终产品碳化硅砖的综合性能; 而且利用这些空隙,高温氮气环境下，Si和N2以气相方式优先在该纤维空间内形成非氧化结合相并获得更好的发育程度，从而在砖体内部形成呈纤维状弥散穿插分布的簇状非氧化物相，并均匀弥散在碳化硅砖内部的结构特征，从而起到增强、增韧的目的。
如果有机纤维过粗则形成的空隙过大，新生成的非氧化物相有可能在其空隙内部填充不足，这将对材料结构带来劣化作用；如果有机纤维过细则不利于氮气顺利进入，新相填充空隙后仍有剩余，则增强、增韧效果有所欠缺。有机纤维过长，则在混料过程中易团成絮状、球状，不利于分散，也无法形成很好的定向分布的非氧化物新相簇状群结构。
其中碳化硅骨料采用98级别，分粗、中、细三个粒级，如2.5-1.43 mm、1.43-0.5mm、0.5-0mm，骨料总量为主料总重量的65-75%；
其中三个粒级可以在一定量下配比，也可只用中、细两个粒级，即1.43-0.5和0.5-0mm，骨料总量仍为主料总重量的65-75%；
其中碳化硅细粉采用98级别，细度为200目和325目两种或其中一种，合计加入量为主料总重量的10~15%。
其中金属硅粉采用98级别，细度为200目、325目、400目中的一种、两种或多种的组合，合计加入量为主料总重量的10~15%。
其中氧化铝微粉采用活性氧化铝微粉，提高反应活性，粒度D50在1~3微米之间。
其中二氧化硅微粉要求SiO2含量大于96%，来自于铁合金冶炼的副产物。
其中防氧化剂形态为325目以下的细粉，种类可为硼酸、碳化硼、五氧化二钒、钠长石、氧化锰等的一种或多种组合。
其中结合剂为酚醛树脂、木质素磺酸钙、木质素磺酸镁、糊精的一种或多种组合。
本发明这种原位定向非氧化物增强碳化硅砖的制备方法为：
步骤一、混料顺序：所有粉料及防氧化剂预混备用;在轮碾机中加入骨料，干混5分钟；加入结合剂干混5分钟；加入水湿混5分钟；加入粉料进一步混20~30分钟；最后拿0.5mm筛网将有机纤维筛入混料机，全部筛入后，继续混合5分钟出料;
步骤二、成形工艺；成形工艺采用正常压制成形，将混合后物料倒入模具内，在一定压力下成形;采用摩擦压砖机、油压机或者人工捣打成形;
步骤三、坯体在200℃干燥48小时后，进行高温氮化烧成，烧成温度为1430~1480℃, 即得到这种原位定向非氧化物增强碳化硅砖。
其中步骤二中因为有机纤维很细小，能够在物料内分布很均匀，且成形对外观没有负面影响，所以可以正常成形。
本发明在创新地现有碳化硅砖工艺基础上，引进有机纤维，有机纤维在低温（低于200度）下可被融化或烧失而留下纤维状空间，高温氮气环境下，Si和N2以气相方式优先在该纤维空间内形成非氧化结合相并获得更好的发育程度，从而在砖体内部形成呈纤维状弥散穿插分布的簇状非氧化物相，从而提高碳化硅砖的强度和韧性。此外，有机纤维带来的气孔效应还能提高氮化反应进行程度，减小或消除砖体表面和内部的氮化反应程度差异，综合提高碳化硅砖的结合和性能。
具体实施方式
对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。
以下实施例详细说明了本发明。
实施例1：
98碳化硅颗粒三个粒级合计70份（20-30-20）、98碳化硅细粉325目15份、98金属硅240目10份、98金属硅400目5份; 外加糊精结合剂3%; 加入的有机纤维为0.2%, 直径30μm，长度4mm;
制备方法为：
步骤一、混料顺序：所有粉料及防氧化剂预混备用。在轮碾机中加入骨料，干混5分钟；加入结合剂干混5分钟；加入水湿混5分钟；加入粉料进一步混20~30分钟；最后拿0.5mm筛网将有机纤维筛入混料机，全部筛入后，继续混合5分钟出料;
步骤二、成形工艺；成形工艺采用正常压制成形，将混合后物料倒入模具内，在一定压力下成形;采用摩擦压砖机、油压机或者人工捣打成形;
步骤三、坯体在200℃干燥48小时后，进行高温氮化烧成，烧成温度为1430~1480℃, 即得到这种原位定向非氧化物增强碳化硅砖。
实施1与原砖性能对比：
Figure 459861DEST_PATH_IMAGE003
实施例2：
98碳化硅颗粒三个粒级合计68份（20-30-20）、98碳化硅细粉325目7份、98金属硅240目10份、98金属硅400目5份; 二氧化硅微粉5份, 外加木质素磺酸钙结合剂2%; 加入的有机纤维为0.2%, 直径30μm，长度4mm;
制备方法为：
步骤一、混料顺序：所有粉料及防氧化剂预混备用。在轮碾机中加入骨料，干混5分钟；加入结合剂干混5分钟；加入水湿混5分钟；加入粉料进一步混20~30分钟；最后拿0.5mm筛网将有机纤维筛入混料机，全部筛入后，继续混合5分钟出料;
步骤二、成形工艺；成形工艺采用正常压制成形，将混合后物料倒入模具内，在一定压力下成形;采用摩擦压砖机、油压机或者人工捣打成形;
步骤三、坯体在200℃干燥48小时后，进行高温氮化烧成，烧成温度为1430~1480℃, 即得到这种原位定向非氧化物增强碳化硅砖。
实施例2与原砖性能对比：
Figure DEST_PATH_IMAGE005

Claims (5)

1.一种原位定向非氧化物增强碳化硅砖，其特征在于：包括主料、防氧化剂和结合剂，主料包括碳化硅骨料和粉料、金属硅、氧化铝微粉、二氧化硅微粉，加入重量份数为：碳化硅骨料和粉料70-85份，金属硅10-25份，氧化铝微粉0-3份, 二氧化硅微粉0-5份; 防氧化剂加入量是主料总重量的0-2%，结合剂加入量是主料总重量的2-5%，有机纤维加入量是主料总重量的0.1-0.5%，有机纤维为防爆纤维，在200度下融化从而形成微细气孔，有机纤维直径20~40μm，长度3~5mm；制备方法为：步骤一、混料顺序：所有粉料及防氧化剂预混备用；在轮碾机中加入骨料，干混5分钟；加入结合剂干混5分钟；加入水湿混5分钟；加入粉料进一步混20~30分钟；最后拿0.5mm筛网将有机纤维筛入混料机，全部筛入后，继续混合5分钟出料;步骤二、成形工艺；成形工艺采用正常压制成形，将混合后物料倒入模具内，在一定压力下成形;采用摩擦压砖机、油压机或者人工捣打成形;步骤三、坯体在200℃干燥48小时后，进行高温氮化烧成，烧成温度为1430~1480℃, 即得到这种原位定向非氧化物增强碳化硅砖。
2.根据权利要求1所述的一种原位定向非氧化物增强碳化硅砖，其特征在于：碳化硅骨料采用98级别，分粗、中、细三个粒级，如2.5-1.43 mm、1.43-0.5 mm、0.5-0mm，骨料总量为主料总重量的65-75%；三个粒级可以在一定量下配比，也可只用中、细两个粒级，即1.43-0.5和0.5-0mm，骨料总量仍为主料总重量的65-75%。
3.根据权利要求1所述的一种原位定向非氧化物增强碳化硅砖，其特征在于：
碳化硅细粉采用98级别，细度为200目和325目两种或其中一种，合计加入量为主料总重量的10~15%。
4.根据权利要求1所述的一种原位定向非氧化物增强碳化硅砖，其特征在于：金属硅粉采用98级别，细度为200目、325目、400目中的一种、两种或多种的组合，合计加入量为主料总重量的10~15%。
5.根据权利要求1所述的一种原位定向非氧化物增强碳化硅砖，其特征在于：二氧化硅微粉要求SiO2含量大于96%，来自于铁合金冶炼的副产物。
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