CN110563477A - 一种原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料及其制备方法 - Google Patents
一种原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料及其制备方法,主要包括以机械法加工的亚微米α氧化铝和单斜氧化锆为基体的复合材料,掺杂稀土添加剂和少量Ca‑Mg‑Zn‑Si体系助烧剂组成的锆铝复合陶瓷材料,通过磨料、干燥、陈腐、成型和烧成等工艺制成,本发明烧成温度低、能够避免外添加纤维或晶须带来的分散不均匀问题,以及相界面结合度差问题。
Description
技术领域
本发明涉及无机非金属陶瓷材料技术领域,尤其涉及一种原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料及其制备方法。
背景技术
陶瓷材料具有较好的强度、耐高温、耐腐蚀、耐磨损以及一些特殊的声、光、电性能,但是脆性大、抗弯折、抗冲击能力较弱是陶瓷材料致命弱点,极大限制了陶瓷材料在各个领域的应用。改善陶瓷材料的脆性是陶瓷材料研究的重要课题,晶须、纤维以其拔出、桥接、裂纹偏转等增韧效应以及自身优异的力学性能对陶瓷材料起到了良好的增强补韧效果,深受广大材料工作者青睐,但绝大多数还是采用外加晶须纤维到陶瓷基体中来增韧陶瓷材料,此种方法会产生以下问题:
首先,晶须纤维在原料研磨分散过程将会受到极大破坏,均匀性也难以得到保证;
其次,添加晶须纤维的粉料流动性变差,高长径比的晶须纤维严重影响陶瓷坯体的成型致密度;
还有,晶须与其它陶瓷材料的烧结致密化控制也是一个难题;
再有,晶须有害身体健康,给原料制备与成型操作工带来严重危害;更不用提昂贵的晶须价格了。
采用原位生长晶须的方法增韧陶瓷材料具有工艺简单,晶粒结合牢固,韧化效果好等特点,十分适用于工业化生产,近年来也得到了广大专家学者的重视。
本申请中所涉及的以机械法加工的亚微米级的α氧化铝为本公司已有专利CN104446509B一种亚微米氧化铝超细粉体串级研磨制备方法所制备的α氧化铝。
发明内容
本发明的目的是克服现有技术的缺点,提供一种烧成温度低、能够避免外添加纤维或晶须带来的分散不均匀问题,以及相界面结合度差问题的一种原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料及其制备方法。
为实现上述发明目的,本发明的技术方案是:
一种原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料,所述复合陶瓷材料主要包括粒度为亚微米级的α氧化铝和单斜氧化锆为基体的复合材料,掺杂稀土添加剂和少量Ca-Mg-Zn-Si体系助烧剂组成的锆铝复合陶瓷材料;所述助烧剂为Ca-Mg-Zn-Si体系助烧剂主要包括CaO、MgO、ZnO和SiO2;所述稀土添加剂为氧化钇、氧化铈;所述α氧化铝、单斜氧化锆、稀土添加剂和Ca-Mg-Zn-Si体系的质量百分比组成为:Al2O3 33-63%、ZrO2 33-63%、Y2O3 1-5%、CeO2 1-8%、CaO 0.1-2%、MgO 0.1-2%、ZnO 0.1-1.0%、SiO2 0.1-1.0%。
一种制备原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料的方法,主要包括以下步骤:
(1)以串级研磨工艺进行超细研磨:将α氧化铝按40-70wt%固含量配浆,加入按0.1-1wt%的助磨剂,以多台高速卧式砂磨机串联不循环方式研磨,控制最终浆料细度D98为500-1500nm;再将得到的浆料按配比与其他剩余原料置于球磨机中,按40-70wt%固含量控制浆料浓度,补充加入0.1-0.5wt%的助磨剂,并调节浆料PH值在9-10之间,混合2-6小时;接着进行多台卧式高速砂磨机串联超细研磨,控制最终浆料细度D98为500-1500nm;
(2)干燥浆料:使用喷雾干燥塔对步骤(1)的浆料进行干燥,得到所需混合粉体;
(3)将干燥后的混合粉体做特殊陈腐处理;将干燥好的混合粉体放置在智能恒温恒湿控制的地下室中,摊放在浅底开口容器中,机器缓慢搅拌以保证混合粉体与空气充分均匀接触,陈腐期为3-15天,得到粉料;
(4)将陈腐好的粉料成型为坯体,在窑炉中按特定烧成曲线烧结;其烧成温度为从室温以2℃/min缓慢升温至500℃排胶,以5℃/min快速升温至1300℃,再2℃/min缓慢升温至目标温度1350-1450℃高温保温1-8小时,再以10℃/min快速降温至1300℃低温保温0.5-5小时,保温结束后随炉自然冷却至室温,即获得所述锆铝复合陶瓷材料。
作为优选,所述步骤(1)中助磨剂为六偏磷酸钠、十二烷基苯磺酸钠和聚甲基丙烯酸铵中的一种或多种。
作为优选,所述步骤(3)中恒温恒湿为温度5-28摄氏度,相对湿度30-85%。
本发明的有益效果是:
第一:通过引入少量的Ca-Mg-Zn-Si系列助烧剂,并结合特定的烧成曲线,锆铝复合陶瓷材料烧结温度从1600±50℃降低至1400±50℃,实现了较低温烧成锆铝复合材料,节能减排,降低成本;
第二:通过添加Ca-Mg-Zn-Si系列助烧剂,诱导锆铝复合陶瓷材料中的α氧化铝原位轴向生长晶须,掺杂稀土添加剂,起到一定的稳定单斜氧化锆和促进烧结作用;
第三:磨料过程经过α氧化铝预先研磨、球磨混合和再超细研磨过程,锆铝分散均匀,原位生长引入的α氧化铝晶须均匀分布在整个材料体系中,且相结合界面良好,避免了外添加纤维或晶须带来的分散不均匀问题以及相界面结合度差问题,工艺简单可行,对比未添加Ca-Mg-Zn-Si助烧剂的锆铝复合陶瓷材料,添加助烧剂后的材料断裂韧性从4.5Mpa•m1/2提高至6.5 Mpa•m1/2,极大的提高了材料的断裂韧性,这正是得益于α氧化铝晶须和单斜氧化锆相变增韧双重韧化特点,再结合本公司的研磨介质球生产工艺,能够实现量产α氧化铝晶须增韧锆铝复合陶瓷研磨球,比重5.0±0.05 g/cm3,直径为3 mm的成品球压碎强度约5000N,断裂韧性为6.51Mpa•m1/2,各方面性能表现优异。
附图说明
图1为实施例1电镜扫描图。
图2为实施例2电镜扫描图。
图3为实施例3电镜扫描图。
图4为实施例4电镜扫描图。
具体实施方式
下面将结合附图对本发明实施例中的技术方案进行清楚、完整地描述。
实施例1:
按以下质量百分比配方组成:Al2O3 35%、ZrO2 57%、Y2O3 1%、CeO2 4.5%、CaO 0.5%、MgO0.8%、ZnO 0.4%、SiO2 0.8%配料;先将所需Al2O3按65wt%固含量配浆,加入0.2wt%六偏磷酸钠和0.1wt%十二烷基苯磺酸钠助磨剂,按一定泵浆速度泵入高速卧式砂磨机中,以多台串联不循环方式研磨,控制最终浆料细度D98为1500nm;再将得到的浆料按配比与其他剩余原料置于球磨机中,控制浆料固含量为60wt%,补充加入0.3wt%聚甲基丙烯酸铵助磨剂,并调节浆料PH值为9,混合2小时;接着继续进行多台卧式高速砂磨机串联超细研磨,控制最终浆料细度D98为1500nm;干燥浆料后得到混合粉体,将混合粉体放置在智能恒温恒湿(温度25摄氏度,相对湿度80%)控制的地下室中,并摊放在浅底开口容器中,机器缓慢搅拌以保证混合粉体与空气充分均匀接触,以达到更快更好的陈腐效果,陈腐期为5天,得到粉料;将所得粉料使用等静压方法成型为坯体;然后在窑炉中从室温以2℃/min缓慢升温至500℃排胶,以5℃/min快速升温至1300℃,再2℃/min缓慢升温至目标温度1430℃高温保温3小时,再以10℃/min快速降温至1300℃低温保温2小时,保温结束后随炉自然冷却至室温,即获得所述原位生长氧化铝晶须锆铝复合陶瓷材料。
实施例2
按以下质量百分比配方组成:Al2O3 46%、ZrO2 47%、Y2O3 2%、CeO2 3%、CaO 0.3%、MgO0.5%、ZnO 0.7%、SiO2 0.5%配料;先将所需Al2O3按55wt%固含量配浆,加入0.1wt%六偏磷酸钠、0.1wt%十二烷基苯磺酸钠和0.1%wt聚甲基丙烯酸铵助磨剂,按一定泵浆速度泵入高速卧式砂磨机中,以多台串联不循环方式研磨,控制最终浆料细度D98为1000nm;再将得到的浆料按配比与其他剩余原料置于球磨机中,控制浆料固含量为50%,补充加入0.1wt%六偏磷酸钠和0.2%wt聚甲基丙烯酸铵助磨剂,并调节浆料PH值为10,混合4小时;接着继续进行多台卧式高速砂磨机串联超细研磨,控制最终浆料细度D98为800nm;干燥浆料后得到混合粉体,将混合粉体放置在智能恒温恒湿(温度20摄氏度,相对湿度70%)控制的地下室中,并摊放在浅底开口容器中,机器缓慢搅拌以保证混合粉体与空气充分均匀接触,以达到更快更好的陈腐效果,储存10天,得到粉料;将所得粉料使用滚制成型方法成型为坯体;然后在窑炉中从室温以2℃/min缓慢升温至500℃排胶,以5℃/min快速升温至1300℃,再2℃/min缓慢升温至目标温度1400℃高温保温4小时,再以10℃/min快速降温至1300℃低温保温4小时,保温结束后随炉自然冷却至室温,即获得所述原位生长氧化铝晶须锆铝复合陶瓷材料。
实施例3
按以下质量百分比配方组成: Al2O3 60%、ZrO2 34%、Y2O3 0.5%、CeO2 3.5%、CaO 0.2%、MgO 0.3%、ZnO 0.5%、SiO2 1%配料;先将所需Al2O3按45wt%固含量配浆,加入0.3wt%六偏磷酸钠和0.1wt%聚甲基丙烯酸铵助磨剂,按一定泵浆速度泵入高速卧式砂磨机中,以多台串联不循环方式研磨,控制最终浆料细度D98为500nm;再将得到的浆料按配比与其他剩余原料置于球磨机中,控制浆料固含量为45wt%,补充加入0.1wt%六偏磷酸钠和0.2wt%聚甲基丙烯酸铵助磨剂,并调节浆料PH值为10,混合6小时;接着继续进行多台卧式高速砂磨机串联超细研磨,控制最终浆料细度D98为500nm;干燥浆料后得到混合粉体,将混合粉体放置在智能恒温恒湿(温度20摄氏度,相对湿度55%)控制的地下室中,并摊放在浅底开口容器中,机器缓慢搅拌以保证混合粉体与空气充分均匀接触,以达到更快更好的陈腐效果,储存15天,得到粉料;将所得粉料使用丸滴成型方法成型为坯体;然后在窑炉中从室温以2℃/min缓慢升温至500℃排胶,以5℃/min快速升温至1300℃,再2℃/min缓慢升温至目标温度1380℃高温保温6小时,再以10℃/min快速降温至1300℃低温保温5小时,保温结束后随炉自然冷却至室温,即获得所述原位生长氧化铝晶须锆铝复合陶瓷材料。
实施例4
按以下质量百分比配方组成:Al2O3 47%、ZrO2 48%、Y2O3 2%、CeO2 3%配料;并按实施例2工艺进行磨料、干燥、陈腐、成型和烧成,烧成阶段将最高保温温度设为1550℃,即获得所述原位生长氧化铝晶须锆铝复合陶瓷材料。
为了更简洁明了说明本发明的实施例及其有益效果,我们对实施例产品进行了相关检测:使用阿基米德排水法测试其比重,使用2L砂磨机测试其自磨损率,使用球团压力机测试其抗压强度,使用维氏硬度计测试其维氏硬度的断裂韧性并且使用电镜扫描方法观测晶须生长状态。
以下结合表1和表2以及附图进一步说明:
表1. 实施例组分表:
表2. 实施例工艺表:
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。基于本发明中的实施例,本领域普通技术人员在没有做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。
Claims (4)
1.一种原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料,其特征在于:所述复合陶瓷材料主要包括粒度为亚微米级的α氧化铝和单斜氧化锆为基体的复合材料,掺杂稀土添加剂和少量Ca-Mg-Zn-Si体系助烧剂组成的锆铝复合陶瓷材料;所述助烧剂为Ca-Mg-Zn-Si体系助烧剂主要包括CaO、MgO、ZnO和SiO2;所述稀土添加剂为氧化钇、氧化铈;所述α氧化铝、单斜氧化锆、稀土添加剂和Ca-Mg-Zn-Si体系的质量百分比组成为:Al2O3 33-63%、ZrO2 33-63%、Y2O3 1-5%、CeO2 1-8%、CaO 0.1-2%、MgO 0.1-2%、ZnO 0.1-1.0%、SiO2 0.1-1.0%。
2.一种制备如权利要求1所述的原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料的方法,其特征在于:主要包括以下步骤:
(1)以串级研磨工艺进行超细研磨:将α氧化铝按40-70wt%固含量配浆,加入按0.1-1wt%的助磨剂,以多台高速卧式砂磨机串联不循环方式研磨,控制最终浆料细度D98为500-1500nm;再将得到的浆料按配比与其他剩余原料置于球磨机中,按40-70wt%固含量控制浆料浓度,补充加入0.1-0.5wt%的助磨剂,并调节浆料PH值在9-10之间,混合2-6小时;接着进行多台卧式高速砂磨机串联超细研磨,控制最终浆料细度D98为500-1500nm;
(2)干燥浆料:使用喷雾干燥塔对步骤(1)的浆料进行干燥,得到所需混合粉体;
(3)将干燥后的混合粉体做特殊陈腐处理;将干燥好的混合粉体放置在智能恒温恒湿控制的地下室中,摊放在浅底开口容器中,机器缓慢搅拌以保证混合粉体与空气充分均匀接触,陈腐期为3-15天,得到粉料;
(4)将陈腐好的粉料成型为坯体,在窑炉中按特定烧成曲线烧结;其烧成温度为从室温以2℃/min缓慢升温至500℃排胶,以5℃/min快速升温至1300℃,再2℃/min缓慢升温至目标温度1350-1450℃高温保温1-8小时,再以10℃/min快速降温至1300℃低温保温0.5-5小时,保温结束后随炉自然冷却至室温,即获得所述锆铝复合陶瓷材料。
3.根据权利要求2所述的一种制备原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料的方法,其特征在于:所述步骤(1)中助磨剂为六偏磷酸钠、十二烷基苯磺酸钠和聚甲基丙烯酸铵中的一种或多种。
4.根据权利要求2所述的一种制备原位生长氧化铝晶须增强补韧锆铝复合陶瓷材料的方法,其特征在于:所述步骤(3)中恒温恒湿为温度5-28摄氏度,相对湿度30-85%。
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