CN109970461B - Ceramic target heating element and manufacturing method thereof - Google Patents
Ceramic target heating element and manufacturing method thereof Download PDFInfo
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Abstract
A ceramic targeted heating element is composed of, by mass, 50-100 parts of ceramic chopped fibers, 0-50 parts of ceramic micro powder, 1-40 parts of high-temperature-resistant clay, 1-15 parts of polyvinylpyrrolidone, 1-10 parts of carboxymethyl cellulose and 8-30 parts of deionized water. The invention takes high temperature resistant and oxidation resistant ceramic chopped fibers such as alumina ceramic chopped fibers, mullite ceramic chopped fibers and the like as main raw materials, can toughen and strengthen on one hand, and can reduce the density on the other hand, thereby realizing the purpose of preparing the light and high-strength ceramic targeted heating element.
Description
Technical Field
The invention belongs to the technical field of ceramic preparation and kiln application, and particularly relates to a ceramic targeted heating element and a manufacturing method thereof.
Background
In the process of firing in the kiln, the calcined product is located at the middle lower part of the kiln, however, due to the natural rising of hot air, heat is generally gathered near the top of the kiln, so that the temperature of the top is obviously higher than that of the middle lower part, and the heat in the kiln cannot be fully utilized, thereby increasing energy consumption and pollutant discharge. Practice proves that the targeted heating element is arranged at the top of the kiln, heat converged to the top of the kiln is reflected to a calcined product by utilizing the heat radiation effect, and the utilization efficiency of energy can be obviously improved.
However, the top of the kiln is a complex and severe high-temperature working condition, the targeted heating element not only bears the erosion of high-temperature hot gas in service, but also bears the action of cold and hot impact, very high requirements are provided for the volume density, the strength, the thermal shock resistance and the like of the targeted heating element, and the annual damage rate of similar products in the market is close to 10 percent. If the targeted heating element can be firmly fixed on the top of the kiln, the volume density of the targeted heating element cannot be too high so as to avoid increasing the load bearing of the top of the kiln and ensure that the targeted heating element cannot be firmly fixed on the top of the kiln, however, the reduction of the density often causes the reduction of the strength, toughness and thermal shock resistance, and the targeted heating element is easy to damage and lose efficacy under the actions of erosion of high-temperature hot gas and cold and hot impact, and cannot realize the expected energy-saving effect.
Disclosure of Invention
Aiming at the technical problem that the density and the strength of the existing ceramic targeted heating element are difficult to be considered at the same time, the invention aims to provide a ceramic targeted heating element and a manufacturing method thereof.
The technical scheme of the invention is as follows:
a ceramic targeted heating element is composed of, by mass, 50-100 parts of ceramic chopped fibers, 0-50 parts of ceramic micro powder, 1-40 parts of high-temperature-resistant clay, 1-15 parts of polyvinylpyrrolidone, 1-10 parts of carboxymethyl cellulose and 8-30 parts of deionized water.
The material comprises, by mass, 60-100 parts of ceramic chopped fibers, 0-30 parts of ceramic micro powder, 3-25 parts of high-temperature-resistant clay, 3-10 parts of polyvinylpyrrolidone, 2-7 parts of carboxymethyl cellulose and 10-25 parts of deionized water.
The ceramic chopped fiber comprises alumina ceramic chopped fiber or mullite ceramic chopped fiber, the length of the ceramic chopped fiber is 0.5-5mm, and the diameter of the ceramic chopped fiber is 1-50 mu m.
The ceramic micro powder comprises alumina ceramic micro powder or mullite ceramic micro powder, the granularity is 1-100 mu m, and the purity is more than or equal to 98 percent.
The refractoriness of the high-temperature resistant clay is more than 1400 ℃, and the high-temperature resistant clay comprises Suzhou soil or Datong soil, and the residue is not more than 5 percent after passing through a 200-mesh sieve.
The K value of the polyvinylpyrrolidone is 70-110.
The preparation method of the ceramic target heating element comprises the following steps,
(1) preparation of plaster mold
The mold of the ceramic targeted heating element is two butted hollow semi-cylindrical gypsum grinding tools, the inner diameter of the gypsum mold is 50-400mm, the outer diameter is 60-500mm, the total height is 80-600mm, the height of the inner cylindrical tool is 50-500mm, a semi-circular through hole is arranged at the center of the bottom of the gypsum mold, the two semi-cylindrical gypsum grinding tools are butted to form a circular through hole, and the diameter of the circular through hole is 5-101 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein a protruding cylindrical positioning rod is fixed at the center of the bottom of the wax core, the positioning rod is matched with a circular through hole at the bottom of a gypsum mold, the outer diameter of the wax core is 44-380mm, the inner diameter of the wax core is 40-370mm, the total height of the wax core is 90-660mm, the height of the positioning rod is 10-150mm, and the diameter of the positioning rod is 4-100 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold to be 3-50mm according to the thickness of the bottom surface of the ceramic targeted heating element;
(4) preparation of ceramic slurry
Weighing ceramic chopped fibers, ceramic micro powder, high-temperature-resistant clay, polyvinylpyrrolidone and carboxymethyl cellulose according to a ratio, adding deionized water, and performing wet ball milling and mixing uniformly;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is higher than the height of the target element green body and is 30-500 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, removing the gypsum mold when a gap is formed between the ceramic target heating element green body and the gypsum mold;
(7) removing wax core
Putting the ceramic target heating element green body and the wax core into an oven at the temperature of 60-70 ℃, preserving heat for 1-3 minutes, and buckling the wax core after the wax core begins to soften;
(8) fettling
Overhauling a ceramic target heating element green body, and cutting off the uneven part on the upper opening surface to form a plane, so that the appearance and the size of the ceramic target heating element conform to the required size;
(9) drying by baking
Fully drying the ceramic target heating element green body;
(10) sintering
And putting the dried ceramic target heating element into a shuttle kiln, preserving the heat for 3-10 hours at 1500-1600 ℃, and sintering to prepare the ceramic target heating element.
The inner diameter of the gypsum mold is 80-350mm, the outer diameter is 100-450mm, the total height is 100-550mm, the height of the inner cylindrical column is 60-450mm, the diameter of the central circular through hole is 10-90mm, the outer diameter of the wax core is 50-320mm, the inner diameter is 40-300mm, and the total height is 100-600mm, wherein the height of the positioning rod is 30-100mm, the diameter of the positioning rod is 9-89mm, the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold is 8-40mm, and the height of the slurry liquid level in the step (5) is 50-450.
The inner diameter of the gypsum mold is 100-300mm, the outer diameter is 110-400mm, the total height is 120-500mm, the height of the inner cylindrical column is 90-400mm, the diameter of the central circular through hole is 18-80mm, the outer diameter of the wax core is 80-280mm, the inner diameter is 70-240mm, and the total height is 120-500mm, wherein the height of the positioning rod is 40-80mm, the diameter of the positioning rod is 17-79mm, the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold is 15-30mm, and the height of the slurry liquid level in the step (5) is 80-400 mm.
In the step (9), the ceramic target heating element green body is firstly placed into a drying chamber with the temperature of 30-40 ℃ for drying for 1-3 hours, and then is placed into a drying chamber with the temperature of 60-80 ℃ for drying for 10-15 hours.
Compared with the prior art, the invention has the technical effects that,
1. the invention takes high temperature resistant and oxidation resistant ceramic chopped fibers such as alumina ceramic chopped fibers, mullite ceramic chopped fibers and the like as main raw materials, can toughen and strengthen on one hand, and can reduce the density on the other hand, thereby realizing the purpose of preparing the light and high-strength ceramic targeted heating element;
2. the added high-temperature-resistant clay can be used as a forming aid and a sintering aid;
3. the ceramic targeted heating element is sintered at the temperature lower than 1600 ℃, although the ceramic targeted heating element cannot be sintered to higher density, the ceramic targeted heating element can be partially densified due to the addition of the high-temperature-resistant and oxidation-resistant alumina ceramic micro powder or mullite ceramic micro powder and the high-temperature-resistant clay, and has higher strength and lower density under the toughening and strengthening effects of the chopped fibers;
4. the ceramic target heating element has the advantages of high temperature resistance, oxidation resistance, low density, high strength, high toughness, low heat conductivity and the like, so that the ceramic target heating element has longer service life, better energy-saving effect and higher comprehensive economic benefit.
Drawings
Fig. 1 is an assembly view of a gypsum mold and wax core of the present invention.
Detailed Description
A ceramic targeted heating element is composed of, by mass, 50-100 parts of ceramic chopped fibers, 0-50 parts of ceramic micro powder, 1-40 parts of high-temperature-resistant clay, 1-15 parts of polyvinylpyrrolidone, 1-10 parts of carboxymethyl cellulose and 8-30 parts of deionized water.
Preferably, 60-100 parts of ceramic chopped fibers, 0-30 parts of ceramic micro powder, 3-25 parts of high-temperature-resistant clay, 3-10 parts of polyvinylpyrrolidone, 2-7 parts of carboxymethyl cellulose and 10-25 parts of deionized water.
Wherein the ceramic chopped fiber comprises alumina ceramic chopped fiber or mullite ceramic chopped fiber, the length of the fiber is 0.5-5mm, and the diameter is 1-50 μm; the ceramic micro powder comprises alumina ceramic micro powder or mullite ceramic micro powder, the granularity of the micro powder is 1-100 mu m, and the purity is more than or equal to 98 percent; the refractoriness of the high-temperature resistant clay is more than 1400 ℃, and the high-temperature resistant clay comprises Suzhou soil or Datong soil, and the residue is not more than 5 percent after being sieved by a 200-mesh sieve; the K value of the polyvinylpyrrolidone is 70-110, and the polyvinylpyrrolidone is industrially pure; the carboxymethyl cellulose is commercially pure.
The raw materials used in the invention are all commercial raw materials.
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
The mold of the ceramic targeted heating element is two butted hollow semi-cylindrical gypsum grinding tools 1, the inner diameter of the gypsum mold 1 is 50-400mm, the outer diameter is 60-500mm, the total height is 80-600mm, the inner cylindrical height is 50-500mm, a semi-circular through hole 3 is arranged at the center of the bottom of the gypsum mold, a circular through hole is formed after the two semi-cylindrical gypsum grinding tools 1 are butted, the wax core is conveniently fixed, meanwhile, a circular through hole is arranged at the center of the bottom surface of the formed targeted heating element, the fixation by a screw is convenient during construction, and the diameter of the circular through hole is 5-101 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core 2, wherein a protruding cylindrical positioning rod 4 is fixed at the center of the bottom of the wax core 2, as shown in figure 1, the positioning rod 4 is matched with a circular through hole at the bottom of a gypsum mold 1, the outer diameter of the wax core is 44-380mm, the inner diameter is 40-370mm, the total height is 90-660mm, the height of the positioning rod is 10-150mm, and the diameter of the positioning rod is 4-100 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds 1, placing a wax core 2 into the gypsum molds 1, adjusting the distance between the lower bottom surface of the wax core 1 and the upper surface of the bottom surface of the gypsum mold to be 3-50mm according to the thickness of the bottom surface of the ceramic targeted heating element, and after the ceramic targeted heating element is assembled, extending a positioning rod 4 into the circular through hole without the bottom of the positioning rod 4 exceeding the gypsum molds;
(4) preparation of ceramic slurry
Weighing ceramic chopped fibers, ceramic micro powder, high-temperature-resistant clay, polyvinylpyrrolidone and carboxymethyl cellulose according to a ratio, adding deionized water, and performing wet ball milling and mixing uniformly;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum so that the liquid level is higher than the height of the ceramic target element green body and is 30-500 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, removing the gypsum mold when a gap is formed between the ceramic target heating element green body and the gypsum mold;
(7) removing wax core
Putting the ceramic target heating element green body and the wax core into an oven at the temperature of 60-70 ℃, preserving heat for 1-3 minutes, and buckling the wax core after the wax core begins to soften;
(8) fettling
Overhauling a ceramic target heating element green body, and cutting off the uneven part on the upper opening surface to form a plane, so that the appearance and the size of the ceramic target heating element conform to the required size;
(9) drying by baking
Fully drying the ceramic target heating element green body, putting the ceramic target heating element green body into a drying chamber at the temperature of 30-40 ℃ for drying for 1-3 hours, and then putting the ceramic target heating element green body into a drying chamber at the temperature of 60-80 ℃ for drying for 10-15 hours;
(10) sintering
And putting the dried ceramic target heating element into a shuttle kiln, preserving the heat for 3-10 hours at 1500-1600 ℃, and sintering to prepare the ceramic target heating element.
Further, the inner diameter of the gypsum mold is 80-350mm, the outer diameter is 100-450mm, the total height is 100-550mm, the height of the inner cylinder is 60-450mm, the diameter of the central circular through hole is 10-90mm, the outer diameter of the wax core is 50-320mm, the inner diameter is 40-300mm, the total height is 100-600mm, the height of the positioning rod is 30-100mm, the diameter of the positioning rod is 9-89mm, the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold is 8-40mm, and the height of the slurry liquid level in the step (5) is 50-450.
Further, the inner diameter of the gypsum mold is 100-300mm, the outer diameter is 110-400mm, the total height is 120-500mm, the height of the inner cylinder is 90-400mm, the diameter of the central circular through hole is 18-80mm, the outer diameter of the wax core is 80-280mm, the inner diameter is 70-240mm, and the total height is 120-500mm, wherein the height of the positioning rod is 40-80mm, the diameter of the positioning rod is 17-79mm, the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold is 15-30mm, and the height of the slurry liquid level in the step (5) is 80-400 mm. In the manufacturing process, the wall thickness and the height of the prepared target heating element can be controlled by adjusting the relative size and the position of the plaster mold and the wax core.
Example 1
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 100mm, the outer diameter is 105mm, the total height is 150mm, the height of the inner cylinder is 130mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 9 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 77.8mm, the inner diameter of the wax core is 70mm, the total height of the wax core is 132mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 8mm, the height of the positioning rod is 17mm, and the positioning rod is matched with a circular through hole in the bottom of a gypsum mold;
(3) assembled grouting forming die
Butt-jointing two hollow semi-cylindrical gypsum molds, placing a wax core into the gypsum molds, controlling the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 11.1mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured, and after the ceramic targeted heating element is assembled, extending a positioning rod into the circular through hole, wherein the bottom of the positioning rod cannot exceed the gypsum molds;
(4) preparation of ceramic slurry
Weighing 100 parts of alumina ceramic chopped fibers, 1 part of alumina ceramic micro powder, 4 parts of Suzhou soil, 4 parts of polyvinylpyrrolidone, 3 parts of carboxymethyl cellulose and 17 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the slurry liquid level descends along with the slurry absorption of the gypsum so that the liquid level is 112mm and the height of the slurry liquid level is slightly larger than that of the ceramic targeting element green body;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap can be formed between the ceramic target heating element green body and the gypsum mold, the gap between the target heating element green body and the gypsum mold wall is observed, and after the target heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the ceramic target heating element green body and the wax core into an oven at the temperature of 60 ℃, preserving heat for 1 minute, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper end opening surface to form a plane;
(9) drying by baking
Putting the repaired ceramic target heating element green body into a drying chamber at 40 ℃ for drying for 3 hours, and then putting the ceramic target heating element green body into a drying chamber at 65 ℃ for drying for 12 hours;
(10) sintering
And (3) placing the dried target heating element into a shuttle kiln, preserving the heat for 6 hours at 1580 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
After detection and use, the inner diameter of the prepared ceramic target heating element is 70.1mm, the outer diameter is 90mm, and the height is 100 mm; the bulk density is 1.05g/cm3The compression strength is 19.8MPa, the thermal conductivity is 3.1W/(mK), and the damage rate is less than 0.2 per mill after the material is used in a soaking furnace at 1400 ℃ for 18 months.
Example 2
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 103.5mm, the outer diameter is 106mm, the total height is 145mm, the height of the inner cylindrical is 130mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 9 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 79.2mm, the inner diameter of the wax core is 72mm, the height of the wax core is 132mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 8mm, the height of the positioning rod is 18mm, and the positioning rod is matched with a circular through hole in the bottom of a gypsum mold;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold to be 11.3mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured, and enabling a positioning rod to extend into a circular through hole, wherein the bottom of the positioning rod cannot exceed the gypsum mold;
(4) preparation of ceramic slurry
Weighing 100 parts of alumina ceramic chopped fibers, 5 parts of alumina ceramic micro powder, 8 parts of Suzhou soil, 5 parts of polyvinylpyrrolidone, 4 parts of carboxymethyl cellulose and 18 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 114.3 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the ceramic targeted heating element and the gypsum mold, and after the green compact of the ceramic targeted heating element is observed to form a gap with the wall of the gypsum mold and has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the ceramic target heating element green body and the wax core into an oven at the temperature of 65 ℃, preserving heat for 1 minute, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the targeted heating element blank to enable the upper end opening surface to be a plane;
(9) drying by baking
Firstly, placing the target heating element green body into a drying chamber at 30 ℃ for drying for 1 hour; then putting the mixture into a drying chamber at 70 ℃ for drying for 13 hours;
(10) sintering
And (3) placing the dried ceramic target heating element into a shuttle kiln, preserving the heat for 6 hours at 1550 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Through detection and use, the inner diameter of the prepared target heating element is 69.9mm, the outer diameter is 89.8mm, the height is 99.9mm, and the volume density is 1.16g/cm3The compression strength is 24.7MPa, the thermal conductivity is 3.6W/(mK), and the damage rate is less than 0.2 per mill after the material is used in a soaking furnace at 1400 ℃ for 18 months.
Example 3
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 100.5mm, the outer diameter is 108mm, the total height is 150mm, the height of the inner cylindrical is 130mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 9 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 78mm, the inner diameter of the wax core is 68mm, the height of the wax core is 132mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 8mm, the height of the positioning rod is 17mm, and the positioning rod is matched with a circular through hole in the bottom of a gypsum mold;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 11.2mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 100 parts of mullite ceramic chopped fibers, 1 part of alumina ceramic micro powder, 4 parts of Suzhou soil, 4 parts of polyvinylpyrrolidone, 3 parts of carboxymethyl cellulose and 17 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 112.2 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, and the gypsum mold is removed after observing that a gap is formed between a green body of the targeted heating element and the wall of the gypsum mold;
(7) removing wax core
Putting the ceramic target heating element green body and the wax core into an oven at the temperature of 70 ℃, preserving heat for 1 minute, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper end opening surface to form a plane;
(9) drying by baking
Firstly, drying the target heating element green body in a drying chamber at 35 ℃ for 3 hours; then drying the mixture in a drying chamber at the temperature of 80 ℃ for 10 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving the heat for 6 hours at 1580 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Through detection and use, the inner diameter of the prepared target heating element is 70mm, the outer diameter is 89.9mm, the height is 100m, and the volume density is 1.10g/cm3The compression strength is 23.5MPa, the thermal conductivity is 3.4W/(mK), and the damage rate is less than 0.2 per mill after the material is used in a soaking furnace at 1400 ℃ for 18 months.
Example 4
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 105mm, the outer diameter is 110mm, the total height is 148mm, the height of the inner cylinder is 130mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 9 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 80mm, the inner diameter of the wax core is 70mm, the height of the wax core is 132mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 8mm, and the height of the positioning rod is 18 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 11.5mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 100 parts of mullite ceramic chopped fibers, 15 parts of mullite ceramic micro powder, 15 parts of kaolin, 6 parts of polyvinylpyrrolidone, 4 parts of carboxymethyl cellulose and 20 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 117 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, the gap between the ceramic targeted heating element green body and the gypsum mold wall is observed, and after the ceramic targeted heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the target heating element green body and the wax core into an oven at the temperature of 68 ℃, preserving heat for 1 minute, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper opening surface to ensure that the upper opening surface is a plane;
(9) drying by baking
Firstly, placing the target heating element green body into a drying chamber at 32 ℃ for drying for 2 hours; then putting the mixture into a drying chamber at 75 ℃ for drying for 11 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving the heat for 6 hours at 1550 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Through detection and use, the prepared target heating element has the inner diameter of 69.3mm, the outer diameter of 89.5mm, the height of 99.7mm, the volume density of 1.42g/cm3, the compression strength of 36.2MPa, the thermal conductivity of 4.5W/(mK), and the damage rate of 18 months in a soaking furnace at 1400 ℃ of less than 0.1 per mill.
From the mixture ratios of the components in examples 1 to 4 and the detection data, the density of the targeted heating element is increased, the compressive strength is increased, and the thermal conductivity is increased along with the increase of the addition amounts of the ceramic micro powder and the high-temperature-resistant clay. The ceramic targeting element has small breakage rate and long service life.
Example 5
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 50mm, the outer diameter is 60mm, the total height is 80mm, the height of an inner cylinder is 50mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 5 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 44mm, the inner diameter of the wax core is 40mm, the height of the wax core is 90mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 4mm, and the height of the positioning rod is 10 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 3mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 50 parts of mullite ceramic chopped fibers, 1 part of kaolin, 1 part of polyvinylpyrrolidone, 1 part of carboxymethyl cellulose and 8 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 30 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, the gap between the ceramic targeted heating element green body and the gypsum mold wall is observed, and after the ceramic targeted heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the target heating element green body and the wax core into an oven at the temperature of 60 ℃, preserving heat for 1 minute, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper opening surface to ensure that the upper opening surface is a plane;
(9) drying by baking
Firstly, placing the target heating element green body into a drying chamber at 30 ℃ for drying for 1 hour; then drying the mixture in a drying chamber at 60 ℃ for 10 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving heat for 3 hours at 1500 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Example 6
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 400mm, the outer diameter is 500mm, the total height is 600mm, the height of an inner cylinder is 500mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 101 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 380mm, the inner diameter of the wax core is 370mm, the height of the wax core is 660mm, a protruding cylindrical positioning rod is reserved in the center of the bottom of the wax core, the diameter of the positioning rod is 100mm, and the height of the positioning rod is 150 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 50mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 100 parts of mullite ceramic chopped fibers, 50 parts of mullite ceramic micro powder, 40 parts of Suzhou soil, 15 parts of polyvinylpyrrolidone, 10 parts of carboxymethyl cellulose and 30 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 500 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, the gap between the ceramic targeted heating element green body and the gypsum mold wall is observed, and after the ceramic targeted heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the target heating element green body and the wax core into an oven at the temperature of 70 ℃, preserving heat for 3 minutes, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper opening surface to ensure that the upper opening surface is a plane;
(9) drying by baking
Firstly, drying the target heating element green body in a drying chamber at 40 ℃ for 3 hours; then putting the mixture into a drying chamber at 80 ℃ for drying for 15 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving the heat for 10 hours at 1600 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Example 7
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 220mm, the outer diameter is 280mm, the total height is 340mm, the height of an inner cylinder is 280mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 53 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 210mm, the inner diameter of the wax core is 200mm, the height of the wax core is 380mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 52mm, and the height of the positioning rod is 80 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 26mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 75 parts of mullite ceramic chopped fibers, 25 parts of alumina ceramic micro powder, 20 parts of kaolin, 8 parts of polyvinylpyrrolidone, 5 parts of carboxymethyl cellulose and 20 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 260 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, the gap between the ceramic targeted heating element green body and the gypsum mold wall is observed, and after the ceramic targeted heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the target heating element green body and the wax core into an oven at the temperature of 70 ℃, preserving heat for 3 minutes, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper opening surface to ensure that the upper opening surface is a plane;
(9) drying by baking
Firstly, drying the target heating element green body in a drying chamber at 40 ℃ for 3 hours; then putting the mixture into a drying chamber at 80 ℃ for drying for 15 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving the heat for 10 hours at 1600 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Example 8
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 300mm, the outer diameter of the mould is 350mm, the total height of the mould is 350mm, the height of an inner cylinder of the mould is 300mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 20 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 200mm, the inner diameter of the wax core is 180mm, the height of the wax core is 400mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 19mm, and the height of the positioning rod is 60 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 40mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 50 parts of alumina ceramic chopped fibers, 40 parts of mullite ceramic micro powder, 20 parts of Suzhou soil, 5 parts of polyvinylpyrrolidone, 5 parts of carboxymethyl cellulose and 15 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry to make the liquid level height be 280mm as the slurry is absorbed by the gypsum and the liquid level of the slurry descends;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, the gap between the ceramic targeted heating element green body and the gypsum mold wall is observed, and after the ceramic targeted heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the target heating element green body and the wax core into an oven at the temperature of 62 ℃, preserving heat for 2 minutes, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper opening surface to ensure that the upper opening surface is a plane;
(9) drying by baking
Firstly, drying the target heating element green body in a drying chamber at 36 ℃ for 2.5 hours; then drying the mixture in a drying chamber at the temperature of 62 ℃ for 14 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving the heat for 5 hours at 1520 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Example 9
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 150mm, the outer diameter is 180mm, the total height is 220mm, the height of an inner cylinder is 200mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 18 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 120mm, the inner diameter of the wax core is 100mm, the height of the wax core is 180mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 17mm, and the height of the positioning rod is 40 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 30mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 90 parts of alumina ceramic chopped fibers, 10 parts of mullite ceramic micro powder, 20 parts of kaolin, 10 parts of polyvinylpyrrolidone, 3 parts of carboxymethyl cellulose and 20 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 180 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, the gap between the ceramic targeted heating element green body and the gypsum mold wall is observed, and after the ceramic targeted heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the target heating element green body and the wax core into an oven at the temperature of 64 ℃, preserving heat for 3 minutes, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper opening surface to ensure that the upper opening surface is a plane;
(9) drying by baking
Firstly, putting the target heating element green body into a drying chamber at 38 ℃ for drying for 1.5 hours; then putting the mixture into a drying chamber at 78 ℃ for drying for 15 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving the heat for 8 hours at 1560 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Example 10
A method of making a ceramic targeted heating element comprising the steps of:
(1) preparation of plaster mold
Preparing two hollow and semi-cylindrical gypsum grinding tools, wherein the inner diameter of the mould is 250mm, the outer diameter is 300mm, the total height is 400mm, the height of an inner cylinder is 300mm, and the diameter of a circular through hole in the center of the lower bottom of the gypsum mould is 50 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein the outer diameter of the wax core is 180mm, the inner diameter of the wax core is 150mm, the height of the wax core is 420mm, a protruding cylindrical positioning rod is reserved in the center of the bottom, the diameter of the positioning rod is 49mm, and the height of the positioning rod is 50 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom of the gypsum mold to be 35mm according to the thickness of the bottom surface of the ceramic targeted heating element to be manufactured;
(4) preparation of ceramic slurry
Weighing 80 parts of alumina ceramic chopped fibers, 35 parts of alumina ceramic micro powder, 10 parts of kaolin, 12 parts of polyvinylpyrrolidone, 8 parts of carboxymethyl cellulose and 8 parts of deionized water, and uniformly mixing by wet ball milling;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is 220 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, a gap is formed between the targeted heating element and the gypsum mold, the gap between the ceramic targeted heating element green body and the gypsum mold wall is observed, and after the ceramic targeted heating element green body has certain strength, the gypsum mold is removed;
(7) removing wax core
Putting the target heating element green body and the wax core into an oven at the temperature of 66 ℃, preserving heat for 1 minute, and buckling the wax core after the wax core is softened;
(8) fettling
Overhauling the target heating element blank, and cutting off the uneven part on the upper opening surface to ensure that the upper opening surface is a plane;
(9) drying by baking
Firstly, placing the target heating element green body into a drying chamber at 30 ℃ for drying for 1.5 hours; then putting the mixture into a drying chamber at 66 ℃ for drying for 13 hours;
(10) sintering
And (3) placing the dried target heating element in a shuttle kiln, preserving the heat for 4 hours at 1580 ℃, and sintering to prepare the low-density and high-strength ceramic target heating element.
Examples 11-15 are shown in table 1:
TABLE 1
Examples 16-22 are shown in Table 2:
TABLE 2
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various changes and modifications can be made without departing from the overall concept of the present invention, and these should also be considered as the protection scope of the present invention.
Claims (6)
1. A ceramic targeted heating element characterized by: the material comprises, by mass, 50-100 parts of ceramic chopped fibers, 0-50 parts of ceramic micro powder, 1-40 parts of high temperature resistant clay, 1-15 parts of polyvinylpyrrolidone, 1-10 parts of carboxymethyl cellulose and 8-30 parts of deionized water; the ceramic chopped fibers comprise alumina ceramic chopped fibers or mullite ceramic chopped fibers, the length of the alumina ceramic chopped fibers is 0.5-5mm, and the diameter of the alumina ceramic chopped fibers is 1-50 mu m; the ceramic micro powder comprises alumina ceramic micro powder or mullite ceramic micro powder, the granularity is 1-100 mu m, and the purity is more than or equal to 98 percent; the high-temperature resistant clay is Suzhou soil or Datong soil with refractoriness of more than 1400 ℃, and the residue after passing through a 200-mesh sieve is not more than 5 percent; the preparation method of the ceramic targeted heating element comprises the following steps,
(1) preparation of plaster mold
The mold of the ceramic targeted heating element is two butted hollow semi-cylindrical gypsum grinding tools, the inner diameter of the gypsum mold is 50-400mm, the outer diameter is 60-500mm, the total height is 80-600mm, the height of the inner cylindrical tool is 50-500mm, a semi-circular through hole is arranged at the center of the bottom of the gypsum mold, the two semi-cylindrical gypsum grinding tools are butted to form a circular through hole, and the diameter of the circular through hole is 5-101 mm;
(2) preparation of wax core
Preparing a hollow cylindrical wax core, wherein a protruding cylindrical positioning rod is fixed at the center of the bottom of the wax core, the positioning rod is matched with a circular through hole at the bottom of a gypsum mold, the outer diameter of the wax core is 44-380mm, the inner diameter of the wax core is 40-370mm, the total height of the wax core is 90-660mm, the height of the positioning rod is 10-150mm, and the diameter of the positioning rod is 4-100 mm;
(3) assembled grouting forming die
Butting two hollow semi-cylindrical gypsum molds, putting a wax core into the gypsum molds, and adjusting the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold to be 3-50mm according to the thickness of the bottom surface of the ceramic targeted heating element;
(4) preparation of ceramic slurry
Weighing ceramic chopped fibers, ceramic micro powder, high-temperature-resistant clay, polyvinylpyrrolidone and carboxymethyl cellulose according to a ratio, adding deionized water, and performing wet ball milling and mixing uniformly;
(5) slip casting
Injecting the slurry prepared by ball milling in the step (4) into an assembled gypsum mould, and supplementing the slurry when the liquid level of the slurry descends along with the slurry absorption of the gypsum to ensure that the liquid level is higher than the height of the target element green body and is 30-500 mm;
(6) plaster removing mould
After the gypsum mold absorbs water, removing the gypsum mold when a gap is formed between the ceramic target heating element green body and the gypsum mold;
(7) removing wax core
Putting the ceramic target heating element green body and the wax core into an oven at the temperature of 60-70 ℃, preserving heat for 1-3 minutes, and buckling the wax core after the wax core begins to soften;
(8) fettling
Overhauling a ceramic target heating element green body, and cutting off the uneven part on the upper opening surface to form a plane, so that the appearance and the size of the ceramic target heating element conform to the required size;
(9) drying by baking
Fully drying the ceramic target heating element green body;
(10) sintering
And putting the dried ceramic target heating element into a shuttle kiln, preserving the heat for 3-10 hours at 1500-1600 ℃, and sintering to prepare the ceramic target heating element.
2. The ceramic targeted heating element of claim 1, wherein: the material comprises, by mass, 60-100 parts of ceramic chopped fibers, 0-30 parts of ceramic micro powder, 3-25 parts of high-temperature-resistant clay, 3-10 parts of polyvinylpyrrolidone, 2-7 parts of carboxymethyl cellulose and 10-25 parts of deionized water.
3. The ceramic targeted heating element of claim 1, wherein: the K value of the polyvinylpyrrolidone is 70-110.
4. The ceramic targeted heating element of claim 1, wherein: the inner diameter of the gypsum mold is 80-350mm, the outer diameter is 100-450mm, the total height is 100-550mm, the height of the inner cylindrical column is 60-450mm, the diameter of the central circular through hole is 10-90mm, the outer diameter of the wax core is 50-320mm, the inner diameter is 40-300mm, and the total height is 100-600mm, wherein the height of the positioning rod is 30-100mm, the diameter of the positioning rod is 9-89mm, the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold is 8-40mm, and the height of the slurry liquid level in the step (5) is 50-450.
5. The ceramic targeted heating element of claim 1, wherein: the inner diameter of the gypsum mold is 100-300mm, the outer diameter is 110-400mm, the total height is 120-500mm, the height of the inner cylindrical column is 90-400mm, the diameter of the central circular through hole is 18-80mm, the outer diameter of the wax core is 80-280mm, the inner diameter is 70-240mm, and the total height is 120-500mm, wherein the height of the positioning rod is 40-80mm, the diameter of the positioning rod is 17-69mm, the distance between the lower bottom surface of the wax core and the upper surface of the bottom surface of the gypsum mold is 15-30mm, and the height of the slurry liquid level in the step (5) is 80-400 mm.
6. The ceramic targeted heating element of claim 1, wherein: in the step (9), the ceramic target heating element green body is firstly placed into a drying chamber with the temperature of 30-40 ℃ for drying for 1-3 hours, and then is placed into a drying chamber with the temperature of 60-80 ℃ for drying for 10-15 hours.
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