CN110156471A - 一种耐磨烧结碳化硅材料及其制造泵部件的方法 - Google Patents
一种耐磨烧结碳化硅材料及其制造泵部件的方法 Download PDFInfo
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Abstract
本发明公开了一种耐磨烧结碳化硅材料及其制造泵部件的方法,涉及碳化硅材料技术领域,本发明耐磨烧结碳化硅材料按其原料重量份计包括:碳化硅80~91份、氮化硼2~5份、微晶刚玉10~25份和半烧熔陶土结合剂,半烧熔陶土结合剂按其原料重量份计包括粘土10~40份、长石40~80份和硼玻璃5~15份,将上述物料按其重量份混合均匀后,将混合料倒入模具中,加8~15MPa的压力,经过压实、烘干、烧结,烧制温度为1100~1380℃,烧制时间为90~120h,将烧制好的坯料再放入到呋喃树脂中浸泡,加2~4MPa的压力,并抽真空,浸泡次数为2~5次,浸泡后能有效的去除烧结过程中产生的气孔,本发明制得的烧结碳化硅泵部件具有耐高温、耐磨损、耐腐蚀等优良特性。
Description
技术领域
本发明涉及碳化硅材料技术领域,更具体的是涉及一种耐磨烧结碳化硅材料及其制造泵部件的方法。
背景技术
泵设备在工业的浆液输送领域具有举足轻重的地位,作为泵的核心,过流部件的材质性能和加工制作质量是直接影响泵的使用寿命和水力性能。过去很长一段时期,我国泵的制造材料和工艺水平处于落后状态,主要市场被国外产品占据,研发优质的泵过流部件材料和先进的生产制造加工工艺,对于改变这种被动局面、提高我国自主装备生产制造能力和水平具有重要的现实意义。
目前用碳化硅材料制作泵主要过流部件,大部分采用树脂填充碳化硅复合和采用烧结碳化硅这两种方式。采用碳化硅填充树脂的方式,受树脂、偶联剂和固化剂影响较大,生产出来的产品气孔较多,耐磨性能不理想,树脂包裹碳化硅颗粒的强度不够,在含固量高的工况介质中,磨损严重,烧结碳化硅耐磨性能等其他方面都要好于树脂复合的碳化硅,但烧结温度高,成品率低,生产的产品出现打压漏的情况,并且极易碎裂。
故如何解决上述技术问题,对于本领域技术人员来说很有现实意义。
发明内容
本发明的目的在于:为了解决上述技术问题,本发明提供一种耐磨烧结碳化硅材料及其制造泵部件的方法。
本发明为了实现上述目的具体采用以下技术方案:
一种耐磨烧结碳化硅材料,按其原料重量份计包括:碳化硅80~91份、氮化硼2~5份、微晶刚玉10~25份和半烧熔陶土结合剂,半烧熔陶土结合剂按其原料重量份计包括粘土10~40份、长石40~80份和硼玻璃5~15份。
一种耐磨烧结碳化硅材料制造泵部件的方法,包括以下步骤:
S1:将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂混合均匀,得到混合料;
S2:将混合好的混合料倒入过流部件模具中并舂实,加8~15MPa的压力进行成型处理,得到过流部件初坯;
S3:将制作好的过流部件初坯进行烘干处理,烘干温度控制为80~100℃,保温时间12~15h;
S4:将烘干好的过流部件初坯进行烧制,烧制温度为1100~1380℃,烧制时间为90~120h;
S5:将烧制好的坯料再放入到呋喃树脂中浸泡,抽真空处理,加2~4MPa的压力,浸泡次数为2~5次。
进一步地,在步骤S1中,依次将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂倒入混料机中进行混料处理。
进一步地,在步骤S4中,烘干好的过流部件初坯放入隧道窑中烧制,采用电炉加热。
进一步地,在步骤S5中,抽真空的真空度为0.095MPa。
本发明的有益效果如下:
1、本发明加入了特制配方的半烧熔陶土结合剂,该半烧熔陶土结合剂的抗黑心能力强,在加热的过程中不会出现过早玻璃化,在加热过程中使部件中的气体和碳素得以充分的氧化,然后烧结成坯料后再将坯料浸入呋喃树脂中,并反复浸泡2~5次,可消除烧结过程中产生的气孔,成品率高,强度高不易碎裂。通过本发明方法制备得到的烧结碳化硅泵过流部件具有耐高温、耐磨损、耐腐蚀、重量轻等优良特性,其使用寿命一般为同等工况条件下高铬合金泵过流部件的4~10倍,并且相比于高铬合金、双相钢和普通碳化硅材料在价格上也较低,用户安装、使用和维护的成本低,市场应用前景大。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明,即所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。通常在此处示出的本发明实施例的组件可以以各种不同的配置来布置和设计。
因此,以下对在本发明的实施例的详细描述并非旨在限制要求保护的本发明的范围,而是仅仅表示本发明的选定实施例。基于本发明的实施例,本领域技术人员在没有做出创造性劳动的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。
需要说明的是,术语“第一”和“第二”等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来,而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且,术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下,由语句“包括一个……”限定的要素,并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。
为了本技术领域的人员更好的理解本发明,下面以下实施例对本发明作进一步详细描述。
实施例1
本实施例提供一种耐磨烧结碳化硅材料,按其原料重量份计包括:碳化硅80份、氮化硼2份、微晶刚玉10份和半烧熔陶土结合剂,半烧熔陶土结合剂按其原料重量份计包括粘土10份、长石40份和硼玻璃5份。
上述一种耐磨烧结碳化硅材料制造泵部件的方法,包括以下步骤:
S1:将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂混合均匀,得到混合料;
S2:将混合好的混合料倒入过流部件模具中并舂实,加8MPa的压力进行成型处理,得到过流部件初坯;
S3:将制作好的过流部件初坯进行烘干处理,烘干温度控制为80℃,保温时间12h;
S4:将烘干好的过流部件初坯进行烧制,烧制温度为1100℃,烧制时间为90h;
S5:将烧制好的坯料再放入到呋喃树脂中浸泡,抽真空处理,加2MPa的压力,浸泡次数为2次。
进一步地,在步骤S1中,依次将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂倒入混料机中进行混料处理。
进一步地,在步骤S4中,烘干好的过流部件初坯放入隧道窑中烧制,采用电炉加热。
进一步地,在步骤S5中,抽真空的真空度为0.095MPa。
实施例2
一种耐磨烧结碳化硅材料,按其原料重量份计包括:碳化硅85份、氮化硼4份、微晶刚玉18份和半烧熔陶土结合剂,半烧熔陶土结合剂按其原料重量份计包括粘土25份、长石60份和硼玻璃10份。
上述一种耐磨烧结碳化硅材料制造泵部件的方法,包括以下步骤:
S1:将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂混合均匀,得到混合料;
S2:将混合好的混合料倒入过流部件模具中并舂实,加10MPa的压力进行成型处理,得到过流部件初坯;
S3:将制作好的过流部件初坯进行烘干处理,烘干温度控制为90℃,保温时间13h;
S4:将烘干好的过流部件初坯进行烧制,烧制温度为1200℃,烧制时间为105h;
S5:将烧制好的坯料再放入到呋喃树脂中浸泡,抽真空处理,加3MPa的压力,浸泡次数为4次。
进一步地,在步骤S1中,依次将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂倒入混料机中进行混料处理。
进一步地,在步骤S4中,烘干好的过流部件初坯放入隧道窑中烧制,采用电炉加热。
进一步地,在步骤S5中,抽真空的真空度为0.095MPa。
实施例3
一种耐磨烧结碳化硅材料,按其原料重量份计包括:碳化硅91份、氮化硼5份、微晶刚玉25份和半烧熔陶土结合剂,半烧熔陶土结合剂按其原料重量份计包括粘土40份、长石80份和硼玻璃15份。
一种耐磨烧结碳化硅材料制造泵部件的方法,包括以下步骤:
S1:将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂混合均匀,得到混合料;
S2:将混合好的混合料倒入过流部件模具中并舂实,加15MPa的压力进行成型处理,得到过流部件初坯;
S3:将制作好的过流部件初坯进行烘干处理,烘干温度控制为100℃,保温时间15h;
S4:将烘干好的过流部件初坯进行烧制,烧制温度为1380℃,烧制时间为120h;
S5:将烧制好的坯料再放入到呋喃树脂中浸泡,抽真空处理,加4MPa的压力,浸泡次数为5次。
进一步地,在步骤S1中,依次将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂倒入混料机中进行混料处理。
进一步地,在步骤S4中,烘干好的过流部件初坯放入隧道窑中烧制,采用电炉加热。
进一步地,在步骤S5中,抽真空的真空度为0.095MPa。
本发明加入了特制配方的半烧熔陶土结合剂,该半烧熔陶土结合剂的抗黑心能力强,在加热的过程中不会出现过早玻璃化,在加热过程中使部件中的气体和碳素得以充分的氧化,然后烧结成坯料后再将坯料浸入呋喃树脂中,并反复浸泡2~5次,可消除烧结过程中产生的气孔,成品率高,强度高不易碎裂,本发明中用到的呋喃树脂在不影响产品要求性能的情况下,可以用环氧树脂或其他树脂代替。通过本发明方法制备得到的烧结碳化硅泵过流部件具有耐高温、耐磨损、耐腐蚀、重量轻等优良特性,其使用寿命一般为同等工况条件下高铬合金泵过流部件的4~10倍,并且相比于高铬合金、双相钢和普通碳化硅材料在价格上也较低,用户安装、使用和维护的成本低,市场应用前景大。
上述实施例1、实施例2和实施例3制得的耐磨烧结碳化硅材料与普通碳化硅材料的力学性能对比如下表1:
表1力学性能对比表
项目 | 实施例1 | 实施例2 | 实施例3 | 普通碳化硅材料 |
抗弯强度(MPa) | 608 | 605 | 610 | 450-500 |
维氏硬度(HV) | 2650 | 2660 | 2650 | 2500 |
断裂韧性(MPa.m<sup>1</sup>/<sup>2</sup>) | 5.5 | 5.6 | 5.4 | 3.5-4.0 |
抗热冲击温差(K) | 1530 | 1550 | 1520 | 1000-1300 |
由上表1可知,本发明制得的耐磨烧结碳化硅材料抗弯强度提高了21%以上,维氏硬度提高了6%以上,断裂韧性提高了35%以上,抗热冲击温差提高了16.9%以上,由该耐磨烧结碳化硅材料制得的泵部件具有耐高温、耐磨损、耐腐蚀等优良特性,满足各种工况使用条件,使用寿命长。
以上所述,仅为本发明的较佳实施例,并不用以限制本发明,本发明的专利保护范围以权利要求书为准,凡是运用本发明的说明书所作的等同变化,同理均应包含在本发明的保护范围内。
Claims (5)
1.一种耐磨烧结碳化硅材料,其特征在于,按其原料重量份计包括:碳化硅80~91份、氮化硼2~5份、微晶刚玉10~25份和半烧熔陶土结合剂,半烧熔陶土结合剂按其原料重量份计包括粘土10~40份、长石40~80份和硼玻璃5~15份。
2.根据权利要求1所述的一种耐磨烧结碳化硅材料制造泵部件的方法,其特征在于,包括以下步骤:
S1:将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂混合均匀,得到混合料;
S2:将混合好的混合料倒入过流部件模具中并舂实,加8~15MPa的压力进行成型处理,得到过流部件初坯;
S3:将制作好的过流部件初坯进行烘干处理,烘干温度控制为80~100℃,保温时间12~15h;
S4:将烘干好的过流部件初坯进行烧制,烧制温度为1100~1380℃,烧制时间为90~120h;
S5:将烧制好的坯料再放入到呋喃树脂中浸泡,抽真空处理,加2~4MPa的压力,浸泡次数为2~5次。
3.根据权利要求2所述的一种耐磨烧结碳化硅材料制造泵部件的方法,其特征在于,在步骤S1中,依次将碳化硅、氮化硼、微晶刚玉和半烧熔陶土结合剂倒入混料机中进行混料处理。
4.根据权利要求2所述的一种耐磨烧结碳化硅材料制造泵部件的方法,其特征在于,在步骤S4中,烘干好的过流部件初坯放入隧道窑中烧制,采用电炉加热。
5.根据权利要求2所述的一种耐磨烧结碳化硅材料制造泵部件的方法,其特征在于,在步骤S5中,抽真空的真空度为0.095MPa。
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