CN109400188B - 一种熔铝炉防渗浇注料及制备方法 - Google Patents
一种熔铝炉防渗浇注料及制备方法 Download PDFInfo
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 60
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 58
- 238000002844 melting Methods 0.000 title claims abstract description 34
- 230000008018 melting Effects 0.000 title claims abstract description 34
- 238000002360 preparation method Methods 0.000 title abstract description 16
- 239000000843 powder Substances 0.000 claims abstract description 57
- 239000002131 composite material Substances 0.000 claims abstract description 35
- 239000004927 clay Substances 0.000 claims abstract description 28
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000000654 additive Substances 0.000 claims abstract description 16
- 230000000996 additive effect Effects 0.000 claims abstract description 15
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 14
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 11
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims description 19
- 239000004568 cement Substances 0.000 claims description 19
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 18
- 229910052851 sillimanite Inorganic materials 0.000 claims description 18
- 239000002994 raw material Substances 0.000 claims description 14
- 229910052593 corundum Inorganic materials 0.000 claims description 11
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 10
- 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 description 7
- ZPWVASYFFYYZEW-UHFFFAOYSA-L dipotassium hydrogen phosphate Chemical compound [K+].[K+].OP([O-])([O-])=O ZPWVASYFFYYZEW-UHFFFAOYSA-L 0.000 claims description 7
- 235000019797 dipotassium phosphate Nutrition 0.000 claims description 7
- 229910000396 dipotassium phosphate Inorganic materials 0.000 claims description 7
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 7
- 239000000395 magnesium oxide Substances 0.000 claims description 7
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 7
- 229920002401 polyacrylamide Polymers 0.000 claims description 4
- 239000002253 acid Substances 0.000 claims description 2
- 235000019982 sodium hexametaphosphate Nutrition 0.000 claims description 2
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 claims description 2
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 claims description 2
- 238000002156 mixing Methods 0.000 abstract description 27
- 238000005266 casting Methods 0.000 abstract description 15
- 239000007788 liquid Substances 0.000 abstract description 15
- 239000000126 substance Substances 0.000 abstract description 7
- 238000000034 method Methods 0.000 abstract description 6
- 239000011159 matrix material Substances 0.000 abstract description 5
- 230000008569 process Effects 0.000 abstract description 4
- 238000005272 metallurgy Methods 0.000 abstract description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 abstract description 2
- 238000005260 corrosion Methods 0.000 abstract 1
- 230000007797 corrosion Effects 0.000 abstract 1
- 239000000463 material Substances 0.000 description 30
- 239000002245 particle Substances 0.000 description 22
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 239000011449 brick Substances 0.000 description 7
- 229910052799 carbon Inorganic materials 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 150000003377 silicon compounds Chemical class 0.000 description 7
- 238000000227 grinding Methods 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- 230000007704 transition Effects 0.000 description 5
- 238000005303 weighing Methods 0.000 description 5
- 239000011819 refractory material Substances 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 239000011148 porous material Substances 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 206010028980 Neoplasm Diseases 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
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Abstract
一种熔铝炉防渗浇注料及制备方法，属于冶金技术领域。使用三氧化二铝在42％～45％的低气孔率焦宝石做浇注料的骨料，采用微粉复合料增强浇注料的抗铝液渗透和侵蚀能力，并调整浇注料的气孔率，采用添加剂改善浇注料中的自密实性；采用减水剂降低浇注料拌和过程中的用水量，采用微胀剂抵抗浇注料高温下的收缩性。本发明熔铝炉用防渗浇注料，提高了浇注体的密度，并在高温下，基质料中能形成一种粘度较大的且性能较好的“液态”物质，这种物质能堵塞浇注体内的气孔，而较好的阻止了高温铝向浇注料本体中渗入，减少了其与浇注料中易反应物质的接触，从而达到防铝液渗透到目的。
Description
技术领域
本发明涉及一种熔铝炉防渗浇注料及制备方法，属于冶金技术领域。
背景技术
熔铝炉的熔池工作过渡层材料在传统的炉衬材料使用上，全部为高铝砖砌筑而成，这种内衬材料会造成很多的砖缝，铝熔液很容易沿砖缝渗入炉衬内部与砖体材料反应，从而破坏炉衬材料，降低了炉体的使用寿命。用浇注料构成的工作过渡层，由于具有炉体的结构整体性好，无砌筑砖的缝隙，且强度高等性能，相对高铝砖而言，使熔铝炉的使用寿命大大提高。由于浇注料的优越性，可代替定型的耐火砖而逐渐用于熔铝炉工作过渡层。
但不管什么样的熔铝炉过渡层衬材，由于长期在高温及温度发生波动的环境下使用，同时根据工艺要求还要添加不同的金属材料入炉进行合金化操作，炉衬被铝液及合金材料的侵蚀、搅拌流动的金属液体的冲刷，加之炉内温度波动频繁造成的热应力作用，会导致耐火材料的剥落损坏，甚至穿漏，致使炉衬维修频繁。特别是高温下，铝液的粘度相当低，其流动性和冲刷性很强，而现有的浇注料抵抗这种高温金属铝向其内部渗透能力较差，金属铝液一旦进入浇注料衬体内部就易与浇注料中的活性易被置换的物质如氧化硅等发生反应，形成铝灰或结成刚玉瘤使体积膨胀，造成衬体溃裂。因此，防止金属铝溶液渗入耐火材料中避免与耐火材料发生反应，避免杂质进入铝合金中影响铝合金质量，降低铝液对衬体材料的附着率，提高浇注的防渗能力，成了熔铝炉过渡层浇注料提高性能的主要研究方向。
发明内容
为了克服现有技术的不足,本发明提供一种熔铝炉防渗浇注料及制备方法。
一种熔铝炉防渗浇注料，包括以下重量份数的原料：
Al2O3含量为42%～45%的低气孔率焦宝石 70～80份；
微粉复合料 20～25份；
微膨胀剂 2～3份；
铝酸钙水泥 2～3份；
添加剂 0.17～0.18份；
减水剂 0.08～0.1份。
微粉复合料组成重量份数比例为：
活性α—氧化铝 38-42份；
氧化镁微粉 18-20份；
钾长石微粉 10-12份；
磷酸氢钾粉 28-32份。
微膨胀剂为硅线石，PCA -200P粉体聚羧酸与六偏磷酸钠复合作为减水剂，添加剂为聚丙烯酰胺PAM。
所述低气孔率焦宝石的Al2O3含量为43%，临界粒径为3mm,最小粒度为0.088mm；所述微粉复合料粒径为0.5μm；所述的微胀剂硅线石粒度为0.02mm。
所述低气孔率焦宝石的颗粒中Al2O3含量为43%，Al2O3的质量百分比含量为≥43%；所述硅线石中的Al2O3质量百分比含量≥50%；所述铝酸钙水泥中Al2O3的质量百分比含量≥72%。
所述低气孔率焦宝石的Al2O3含量为45%，临界粒径为5mm,最小粒度为0.088mm；所述微粉复合料粒径为0.5μm；所述的微胀剂硅线石粒度为0.02mm。
所述的低气孔率焦宝石颗粒的Al2O3含量为45%，Al2O3的质量百分比含量为≥45%；所述硅线石中的Al2O3质量百分比含量≥50%；所述铝酸钙水泥中Al2O3的质量百分比含量≥72%。
所述低气孔率焦宝石的Al2O3含量为45%，临界粒径为5mm,最小粒度为0.088mm；所述微粉复合料粒径为0.5μm；所述的微胀剂硅线石粒度为0.02mm； Al2O3的质量百分比含量为≥45%；所述硅线石中的Al2O3质量百分比含量≥50%；所述铝酸钙水泥中Al2O3的质量百分比含量≥72%。
一种熔铝炉防渗浇注料制备方法,使用三氧化二铝在42%～45%的低气孔率焦宝石做浇注料的骨料，采用微粉复合料增强浇注料的抗铝液渗侵能力，并调整浇注料的气孔率，采用添加剂改善浇注料中的自密实性；采用减水剂降低浇注料拌和过程中的用水量，采用微胀剂有抗浇注料高温下的收缩性。
一种熔铝炉防渗浇注料制备方法，熔铝炉防渗浇注料重量配比如下：
Al2O3含量为42%～45%低气孔率焦宝石 70～80份；
微粉复合料 20～25份；
微膨胀剂 2～3份；
铝酸钙水泥 2～3份；
添加剂 0.17～0.18份；
减水剂 0.08～0.1份；
含有以下步骤；
步骤1、按照上述配方称取各原料，备用；
步骤2、将微粉复合料按重量份数比例：
活性α—氧化铝 38-42；
氧化镁微粉 18-20；
钾长石微粉 8-10；
磷酸氢钾粉 28-30；放入在球磨机中共混研磨1小时，制得微粉复合料；
步骤3、将Al2O3含量为42%低气孔率焦宝石的各种不同颗粒料、硅线石先于搅拌机中混合混5分钟后，再将适量的水与混合机中的料混合5分钟，再加入微粉复合料进行混合5分钟，最后加入纯铝酸钙水泥、添加剂和剩余的水，共搅拌时间为15-20分钟，进行现场浇注。
本发明的防渗浇注料在以下三个方面有明显体现；
1、选用低气孔率焦宝石作为主要原料，降低熔铝炉用浇注料在使用时与高温熔融铝液的反应问题。减少浇注料骨料材料与熔液中的金属铝反应生成铝灰，使熔铝炉衬体材料使用寿命提高，这是与目前熔铝炉用浇注料所不同的。
2、在浇注料中加入提前预混好的复合超细粉，使其在高温下易形成高粘度“液相”降低熔铝炉浇注料的气孔率和气孔孔径，防止铝液的渗透进入衬体材料中。
3、使炉衬材料内部的颗粒料与浇注料基质材料进行反应，在骨料表面成形成一屋保护层，减少高温铝液与烧注料中的主体耐火材料反生反应，提高铝合金的质量。
本发明熔铝炉用防渗浇注料,在使用的过程中，通过原料中的骨料与基质中的复合料的相互反应发挥作用，在增稠的作用下增强了提高了浇注料的低气孔率性，使浇注料显示了优良的抵抗金属铝熔液向浇注料内侵渗的能力，从而提高了熔铝炉浇注炉衬的使用；且该浇注料制备过程简单，原料易得。
本发明熔铝炉用防渗浇注料，提高了浇注体的密度，并在高温下，基质料中能形成一种粘度较大的且性能较好的“液态”物质，这种物质能堵塞浇注体内的气孔，而较好的阻止了高温铝向浇注料本体中渗入，减少了其与浇注料中易反应物质的接触，从而达到防铝液渗透到目的。
具体实施方式
显然，本领域技术人员基于本发明的宗旨所做的许多修改和变化属于本发明的保护范围。
本技术领域技术人员可以理解，除非特意声明，这里使用的所有术语（包括技术术语和科学术语）具有与所属领域中的普通技术人员的一般理解相同的意义。
为便于对实施例的理解，下面将结合做进一步的解释说明，且各个实施例并不构成对本发明的限定。
实施例1：一种熔铝炉防渗浇注料，包括以下重量份数的原料：Al2O3含量为42%低气孔率焦宝石75份、微粉复合料20份、硅线石3份、铝酸钙水泥2份、添加剂0.17份、减水剂0.1份。
所述Al2O3含量为42%低气孔率焦宝石的临界粒径为5mm,最小粒度为0.088mm；所述复合微粉粒径为0.5μm；所述的微胀剂硅线石粒度为0.02mm。
所述的Al2O3含量为42%低气孔率焦宝石颗粒中Al2O3的质量百分比含量为≥42%；所述硅线石中的Al2O3质量百分比含量≥50%；所述纯铝酸钙水泥中Al2O3的质量百分比含量≥72%。
熔铝炉用防渗浇注料的制备方法，包括以下步骤：
步骤1、按照上述配方称取各原料，备用；
步骤2、将微粉复合料按比例：活性α—氧化铝：氧化镁微粉：钾长石微粉：磷酸氢钾粉： =42：20：10：30。在球磨机中共混研磨1小时，制得微粉复合料。
步骤3、将Al2O3含量为42%低气孔率焦宝石的各种不同颗粒料、硅线石先于搅拌机中混合混5分钟后，再将适量的水与混合机中的料混合5分钟，再加入微粉复合料进行混合5分钟，最后加入纯铝酸钙水泥、添加剂和剩余的水，共搅拌时间为15-20分钟年进行现场浇注。
步骤3为熔铝炉浇注料的现场制备过程。
实施例2：一种熔铝炉防渗浇注料，包括以下重量份数的原料：Al2O3含量为43%低气孔率焦宝石72份、微粉复合料23份、硅线石2份、铝酸钙水泥3份、添加剂0.18份、减水剂0.08份。
所述Al2O3含量为43%低气孔率焦宝石的临界粒径为3mm,最小粒度为0.088mm；所述复合微粉粒径为0.5μm；所述的微胀剂硅线石粒度为0.02mm。
所述的Al2O3含量为43%低气孔率焦宝石颗粒中Al2O3的质量百分比含量为≥43%；所述硅线石中的Al2O3质量百分比含量≥50%；所述纯铝酸钙水泥中Al2O3的质量百分比含量≥72%。
熔铝炉用防渗浇注料的制备方法，包括以下步骤：
步骤1、按照上述配方称取各原料，备用；
步骤2、将微粉复合料按比例：活性α—氧化铝：氧化镁微粉：钾长石微粉：磷酸氢钾粉： =40：19：10：29。在球磨机中共混研磨1小时，制得微粉复合料。
步骤3、将Al2O3含量为43%低气孔率焦宝石的各种不同颗粒料、硅线石先于搅拌机中混合混5分钟后,再将适量的水与混合机中的料混合5分钟，再加入微粉复合料进行混合6分钟，最后加入纯铝酸钙水泥、添加剂和剩余的水，共搅拌时间为15-20分钟年进行现场浇注。
步骤3为熔铝炉浇注料的现场制备过程。
实施例3：一种熔铝炉防渗浇注料，包括以下重量份数的原料：Al2O3含量为45%低气孔率焦宝石70份、微粉复合料21份、硅线石2份、铝酸钙水泥3份、添加剂0.17份、减水剂0.09份。
所述Al2O3含量为45%低气孔率焦宝石的临界粒径为5mm,最小粒度为0.088mm；所述复合微粉粒径为0.5μm；所述的微胀剂硅线石粒度为0.02mm。
所述的Al2O3含量为45%低气孔率焦宝石颗粒中Al2O3的质量百分比含量为≥45%；所述硅线石中的Al2O3质量百分比含量≥50%；所述纯铝酸钙水泥中Al2O3的质量百分比含量≥72%。
熔铝炉用防渗浇注料的制备方法，包括以下步骤：
步骤1、按照上述配方称取各原料，备用；
步骤2、将微粉复合料按比例：活性α—氧化铝：氧化镁微粉：钾长石微粉：磷酸氢钾粉： =38：18：8：28。在球磨机中共混研磨1.2小时，制得微粉复合料。
步骤3、将Al2O3含量为45%低气孔率焦宝石的各种不同颗粒料、硅线石先于搅拌机中混合混5分钟后,再将适量的水与混合机中的料混合5分钟，再加入微粉复合料进行混合6分钟，最后加入纯铝酸钙水泥、添加剂和剩余的水，共搅拌时间为15-20分钟年进行现场浇注。
步骤3为熔铝炉浇注料的现场制备过程。
实施例4：一种熔铝炉防渗浇注料，包括以下重量份数的原料：Al2O3含量为45%低气孔率焦宝石80份、微粉复合料25份、硅线石2份、铝酸钙水泥3份、添加剂0.17份、减水剂0.08份。
所述Al2O3含量为45%低气孔率焦宝石的临界粒径为5mm,最小粒度为0.088mm；所述复合微粉粒径为0.5μm；所述的微胀剂硅线石粒度为0.02mm。
所述的Al2O3含量为45%低气孔率焦宝石颗粒中Al2O3的质量百分比含量为≥45%；所述硅线石中的Al2O3质量百分比含量≥50%；所述纯铝酸钙水泥中Al2O3的质量百分比含量≥72%。
熔铝炉用防渗浇注料的制备方法，包括以下步骤：
步骤1、按照上述配方称取各原料，备用；
步骤2、将微粉复合料按比例：活性α—氧化铝：氧化镁微粉：钾长石微粉：磷酸氢钾粉： =38：18：8：28。在球磨机中共混研磨1.2小时，制得微粉复合料。
步骤3、将Al2O3含量为45%低气孔率焦宝石的各种不同颗粒料、硅线石先于搅拌机中混合混5分钟后,再将适量的水与混合机中的料混合5分钟，再加入微粉复合料进行混合6分钟，最后加入纯铝酸钙水泥、添加剂和剩余的水，共搅拌时间为15-20分钟年进行现场浇注。
步骤3为熔铝炉浇注料的现场制备过程。
如上所述，对本发明的实施例进行了详细地说明，但是只要实质上没有脱离本发明的发明点及效果可以有很多的变形，这对本领域的技术人员来说是显而易见的。因此，这样的变形例也全部包含在本发明的保护范围之内。
Claims (1)
1.一种熔铝炉防渗浇注料，其特征在于包括以下重量份数的原料：
Al2O3含量为42%～45%的低气孔率焦宝石 70～80份；
微粉复合料 20～25份；
微膨胀剂 2～3份；
铝酸钙水泥 2～3份；
添加剂 0.17～0.18份；
减水剂 0.08～0.1份；
微粉复合料组成重量份数比例为：
活性α—氧化铝 38-42份；
氧化镁微粉 18-20份；
钾长石微粉 10-12份；
磷酸氢钾粉 28-32份；
微膨胀剂为硅线石，PCA -200P粉体聚羧酸与六偏磷酸钠复合作为减水剂，添加剂为聚丙烯酰胺PAM。
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