CN110937899A - 一种Al2O3-ZrO2碳滑板材料制备方法 - Google Patents
一种Al2O3-ZrO2碳滑板材料制备方法 Download PDFInfo
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Abstract
本发明涉及碳滑板制备技术领域,更具体而言,涉及一种Al2O3‑ZrO2碳滑板制备方法。通过在原料沥青焦中加入Al2O3、ZrO2、Al2O3‑SiO2、SiC、炭黑、特种石墨粉等,与原料中的其他材料相融合,可以补充成品碳滑板的机械强度,使其在运行中不易折断和破裂;其制备工艺是,首先对原料进行研磨,再通过模压成型、浸渍工艺、烧结炭化、通电纯化处理,可以增加碳滑条材料的密度和强度。其体积密度≤4g/cm3、抗折强度≥80、抗压强度≥160、冲击韧性≥0.2J/cm2、20℃电阻率≤10µΩ·m、洛氏硬度(HBS)≤100。
Description
技术领域
本发明涉及碳滑板制备技术领域,更具体而言,涉及一种Al2O3-ZrO2碳滑板材料制备方法。
背景技术
受电弓滑板是电力机车上的重要集电元件,安装在受电弓的最上部,直接与接触网导线接触,在列车走行过程中,从接触网导线上获得电流为机车供应电力。
受电弓碳滑板碳滑条材料必须具有良好的减磨性和自润滑性、良好的耐热和耐电弧性、一定的耐磨性、足够的抗冲击强度以及稳定的电阻率和接触电阻。
现如今电力机车受电弓碳滑板分为三种:粉末冶金滑板、纯碳滑板、碳基复合材料滑板。其中碳基复合材料为浸金属碳材料、碳纤维材料及MCC材料或陶瓷材料。
碳滑条材料综合性能是其必备条件,其中高强度、高韧性、低电阻、耐磨以及自润滑特性的滑动电接触材料是最佳选择。Al2O3-ZrO2碳滑板材料具有抗热性强、热膨胀率低、密度、硬度、弹性模量、抗弯强度均优于各单一材料。利用其制备的碳滑板各项性能指标满足国标要求,且工艺简单、效率高。
发明内容
为了克服现有技术中所存在的不足,本发明提供一种Al2O3-ZrO2碳滑板材料制备方法,以提高受电弓碳滑条材料的机械强度、电导性和耐冲击性能。
为了解决上述技术问题,本发明所采用的技术方案为:
一种Al2O3-ZrO2碳滑板材料制备方法,包括以下步骤:
S1、研磨:将Al2O3、ZrO2、SiC、Al2O3-SiO2、碳黑、特种石墨粉混合后置于球磨机中,充入氮气,在150-300℃温度下进行球磨2-6h;
S2、混捏:将S1中研磨后混合粉料与沥青焦混捏,混捏温度为160℃-220℃,混捏时间为1-5h;
S3、湿混:在S2中混捏后混合粉料加入粘结剂进行湿混,温度为120-170℃,湿混时间为40-60分钟;
S4、模压成型:将S3中湿混后材料倒入模具中,利用双向压制模压成型制成一定形状和尺寸的压坯,并使之具有一定的密度和强度。压机为630T以上压机,利用冷却设备对碳滑板初坯进行冷却处理。
S5、焙烧:将S4模压成型后生坯装入焙烧炉中进行焙烧得到第一次坯体;
S6、浸渍:将S5焙烧后第一次坯体称重后置入石墨坩埚中,加入中温沥青,将石墨坩埚放入真空设备中,确保无误后开始抽真空,当真空度达到0.085MPa后,真空结束,再次放入预热炉中预热半小时至室温后取出;
S7、二次焙烧:将S6中浸渍后的坯体放入焙烧炉中进行第二次焙烧得到第二次坯体,焙烧温度为20℃-1200℃,并在1200℃温度下保温4h,焙烧时间为16h;
S8、烧结:将S7中二次焙烧后碳滑条材料放入烧结炉中,使钢碳完全包裹,然后充入保护气氩气,直到压力达到15-20兆帕,然后加热至1000-1250摄氏度,保持24-32小时后取出;
S9、将S8中烧结后碳滑条材料在隔绝空气的条件下,通过电加热到550-700℃,电流强度为15A,保持6-8小时,填充材料内部微气孔,形成晶须,制得纯净的Al2O3-ZrO2碳滑板材料。
进一步地,所述Al2O3粉的粒度为1-10μm;ZrO2粉的粒度D为1-15μm;SiC粉的粒度为1-20μm、密度3.2g/cm3;Al2O3-SiO2的粒度为1-30μm;碳黑的粒度为1-40μm;特种石墨粉的粒度为1-50μm,真密度≥2.0g/cm3,电阻率≤8.0μΩm,抗折强度≥25Mpa,抗压强度≥35Mpa,灰分≤0.20%;沥青焦的粒度为1-60μm,真密度≥2.13g/cm3,灰分≤0.25%、含硫量≤0.3%、挥发份≤0.5%;浸渍剂中温煤沥青为软化点为83-89℃,结焦值为≥58%,灰分≤0.30%;所述粘结剂采用酚醛树脂,软化点为105-120℃。
进一步地,所述沥青焦的粒度为1-10μm占其重量的10%,粒度为10-20μm占其重量的20%,粒度为20-30μm占其重量的20%,粒度为30-40μm占其重量的20%,粒度为40-50μm占其重量的20%,粒度为50-60μm占其重量的10%;Al2O3的粒度为1-3μm占其重量的20%,粒度为3-5μm占其重量的30%,粒度为5-8μm占其重量的30%,粒度为8-10μm占其重量的20%;ZrO2的粒度为1-5μm占其重量的35%,粒度为5-10μm占其重量的30%,粒度为10-15μm占其重量的35%;SiC的粒度为1-5μm占其重量的15%,粒度为5-10μm占其重量的35%,粒度为10-15μm占其重量的35%,粒度为15-20μm占其重量的15%;Al2O3-SiO2的粒度为1-5μm占其重量的10%,粒度为5-10μm占其重量的20%,粒度为10-15μm占其重量的20%,粒度为15-20μm占其重量的20%,粒度为20-25μm占其重量的20%,粒度为25-30μm占其重量的10%;碳黑的粒度为1-10μm占其重量的25%,粒度为10-20μm占其重量的25%,粒度为20-30μm占其重量的25%,粒度为30-40μm占其重量的25%;特种石墨粉的粒度为1-10μm占其重量的10%,粒度为10-20μm占其重量的20%,粒度为20-30μm占其重量的25%,粒度为30-40μm占其重量的25%,粒度为40-50μm占其重量的20%。
进一步地,所述Al2O3、ZrO2、SiC、Al2O3-SiO2、碳黑、特种石墨粉的混合料,其重量比为8:5:12:20:25:30;研磨后混合粉料与沥青焦重量比为40:60;混捏后混合粉料与粘结剂重量比为70:30-75:25。
进一步地,所述混捏机置有自动报警装置,且自动报警装置用于设定时间到达时进行报警。
进一步地,所述S5中焙烧的升温程序为:焙烧温度为20℃-1250℃,室温-100℃,按照100℃/h升温,保持1h;100-200℃,按照100℃/h升温,保持1h;200℃-900℃、按照100℃/h升温,保持7h;900℃-1250℃、按照按照150℃/h升温,保持2h;并在1250℃温度下保温4h,然后自然冷却
进一步地,所述S6中温沥青在加入前进行融化,在预热炉中坩埚加热的过程当中,准备沥青融化,通电前检查电路、水路是否畅通。增重率为30-33%。
进一步地,所述S7二次焙烧前,利用烘干设备对浸渍处理后的烧结碳滑条材料初坯进行烘干处理。
进一步地,所制备的Al2O3-ZrO2碳滑板制备方法,其体积密度≤4g/cm3、抗折强度≥80、抗压强度≥160、冲击韧性≥0.2J/cm2、20℃电阻率≤10µΩ·m、洛氏硬度(HBS)≤100。
与现有技术相比,本发明所具有的有益效果为:
本发明提供了一种Al2O3-ZrO2碳滑板制备方法。通过在原料沥青焦中加入Al2O3、ZrO2、Al2O3-SiO2、SiC、碳黑、特种石墨粉等,与原料中的其他材料相融合,可以补充成品碳滑板的机械强度,使其在运行中不易折断和破裂,所制备的碳滑板组织致密、气孔微细、耐侵蚀性好,具备优异的机械强度和耐磨性;其制备工艺是,首先对原料进行研磨,再通过模压成型、浸渍工艺、烧结炭化、通电纯化处理,可以增加碳滑条材料的密度和强度。其体积密度≤4g/cm3、抗折强度≥80、抗压强度≥160、冲击韧性≥0.2J/cm2、20℃电阻率≤10µΩ·m、洛氏硬度(HBS)≤100。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述,显然,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。
一种Al2O3-ZrO2碳滑板材料制备方法,包括以下步骤:
S1、研磨:将Al2O3、ZrO2、SiC、Al2O3-SiO2、碳黑、特种石墨粉混合后置于球磨机中,充入氮气,在150-300℃温度下进行球磨2-6h;所述Al2O3粉的粒度为1-10μm;ZrO2粉的粒度D为1-15μm;SiC粉的粒度为1-20μm、密度3.2g/cm3;Al2O3-SiO2的粒度为1-30μm;碳黑的粒度为1-40μm;特种石墨粉的粒度为1-50μm,真密度≥2.0g/cm3,电阻率≤8.0μΩm,抗折强度≥25Mpa,抗压强度≥35Mpa,灰分≤0.20%;所述Al2O3、ZrO2、SiC、Al2O3-SiO2、碳黑、特种石墨粉重量比为8:5:12:20:25:30;
S2、混捏:将S1中研磨后混合粉料与沥青焦混捏,重量比为40:60;混捏温度为160℃-220℃,混捏时间为1-5h;沥青焦的粒度为1-60μm,真密度≥2.13g/cm3,灰分≤0.25%、含硫量≤0.3%、挥发份≤0.5%;混捏机设置有自动报警装置,且自动报警装置用于设定时间到达时进行报警
S3、湿混:在S2中混捏后混合粉料加入粘结剂进行湿混,重量比为70:30-75:25;温度为120-170℃,湿混时间为40-60分钟;所述粘结剂采用酚醛树脂,软化点为105-120℃;
S4、模压成型:将S3中湿混后材料倒入模具中,利用双向压制模压成型制成一定形状和尺寸的压坯,并使之具有一定的密度和强度。压机为630T以上压机,利用冷却设备对碳滑板初坯进行冷却处理。
S5、焙烧:将S4模压成型后生坯装入焙烧炉中进行焙烧得到第一次坯体;焙烧的升温程序为:焙烧温度为20℃-1250℃,室温-100℃,按照100℃/h升温,保持1h;100-200℃,按照100℃/h升温,保持1h;200℃-900℃、按照100℃/h升温,保持7h;900℃-1250℃、按照按照150℃/h升温,保持2h;并在1250℃温度下保温4h,然后自然冷却;
S6、浸渍:将S5焙烧后第一次坯体称重后置入石墨坩埚中,加入中温沥青,将石墨坩埚放入真空设备中,确保无误后开始抽真空,当真空度达到0.085MPa后,真空结束,再次放入预热炉中预热半小时至室温后取出;中温煤沥青为软化点为83-89℃,结焦值为≥58%,灰分≤0.30%;中温沥青在加入前进行融化,在预热炉中坩埚加热的过程当中,准备沥青融化,通电前检查电路、水路是否畅通。增重率为30-33%。
S7、二次焙烧:将S6中浸渍后的坯体放入焙烧炉中进行第二次焙烧得到第二次坯体,焙烧温度为20℃-1200℃,并在1200℃温度下保温4h,焙烧时间为16h;焙烧前,利用烘干设备对浸渍处理后的烧结碳滑条材料初坯进行烘干处理。
S8、烧结:将S7中二次焙烧后碳滑条材料放入烧结炉中,使钢碳完全包裹,然后充入保护气氩气,直到压力达到15-20兆帕,然后加热至1000-1250摄氏度,保持24-32小时后取出;
S9、将S8中烧结后碳滑条材料在隔绝空气的条件下,通过电加热到550-700℃,电流强度为15A,保持6-8小时,制得Al2O3-ZrO2碳滑板材料。
在本实施例中,所述沥青焦的粒度为1-10μm占其重量的10%,粒度为10-20μm占其重量的20%,粒度为20-30μm占其重量的20%,粒度为30-40μm占其重量的20%,粒度为40-50μm占其重量的20%,粒度为50-60μm占其重量的10%;Al2O3的粒度为1-3μm占其重量的20%,粒度为3-5μm占其重量的30%,粒度为5-8μm占其重量的30%,粒度为8-10μm占其重量的20%;ZrO2的粒度为1-5μm占其重量的35%,粒度为5-10μm占其重量的30%,粒度为10-15μm占其重量的35%;SiC的粒度为1-5μm占其重量的15%,粒度为5-10μm占其重量的35%,粒度为10-15μm占其重量的35%,粒度为15-20μm占其重量的15%;Al2O3-SiO2的粒度为1-5μm占其重量的10%,粒度为5-10μm占其重量的20%,粒度为10-15μm占其重量的20%,粒度为15-20μm占其重量的20%,粒度为20-25μm占其重量的20%,粒度为25-30μm占其重量的10%;碳黑的粒度为1-10μm占其重量的25%,粒度为10-20μm占其重量的25%,粒度为20-30μm占其重量的25%,粒度为30-40μm占其重量的25%;特种石墨粉的粒度为1-10μm占其重量的10%,粒度为10-20μm占其重量的20%,粒度为20-30μm占其重量的25%,粒度为30-40μm占其重量的25%,粒度为40-50μm占其重量的20%。
在本实施例中,所制备的Al2O3-ZrO2碳滑板制备方法,其体积密度≤4g/cm3、抗折强度≥80、抗压强度≥160、冲击韧性≥0.2J/cm2、20℃电阻率≤10µΩ·m、洛氏硬度(HBS)≤100。
上面仅对本发明的较佳实施例作了详细说明,但是本发明并不限于上述实施例,在本领域普通技术人员所具备的知识范围内,还可以在不脱离本发明宗旨的前提下作出各种变化,各种变化均应包含在本发明的保护范围之内。
Claims (8)
1.一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于,包括以下步骤:
S1、研磨:将Al2O3、ZrO2、SiC、Al2O3-SiO2、碳黑、特种石墨粉混合后置于球磨机中,充入氮气,在150-300℃温度下进行球磨2-6h;
S2、混捏:将S1中研磨后混合粉料与沥青焦混捏,混捏温度为160℃-220℃,混捏时间为1-5h;
S3、湿混:在S2中混捏后混合粉料加入粘结剂进行湿混,温度为120-170℃,湿混时间为40-60分钟;
S4、模压成型:将S3中湿混后材料倒入模具中,利用双向压制模压成型制成一定形状和尺寸的压坯,并使之具有一定的密度和强度,压机为630T以上压机,利用冷却设备对碳滑板初坯进行冷却处理;
S5、焙烧:将S4模压成型后生坯装入焙烧炉中进行焙烧得到第一次坯体;
S6、浸渍:将S5焙烧后第一次坯体称重后置入石墨坩埚中,加入中温沥青,将石墨坩埚放入真空设备中,确保无误后开始抽真空,当真空度达到0.085MPa后,真空结束,再次放入预热炉中预热半小时,降至室温后取出;
S7、二次焙烧:将S6中浸渍后的坯体放入焙烧炉中进行第二次焙烧得到第二次坯体,焙烧温度为20℃-1200℃,并在1200℃温度下保温4h,焙烧时间为16h;
S8、烧结:将S7中二次焙烧后碳滑条材料放入烧结炉中,使钢碳完全包裹,然后充入保护气氩气,直到压力达到15-20兆帕,然后加热至1000-1250摄氏度,保持24-32小时后取出;
S9、将S8中烧结后碳滑条材料在隔绝空气的条件下,通过电加热到550-700℃,电流强度为15A,保持6-8小时,制得Al2O3-ZrO2碳滑板材料。
2.根据权利要求1所述的一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于:所述Al2O3粉的粒度为1-10μm;ZrO2粉的粒度D为1-15μm;SiC粉的粒度为1-20μm、密度3.2g/cm3;Al2O3-SiO2的粒度为1-30μm;碳黑的粒度为1-40μm;特种石墨粉的粒度为1-50μm,真密度≥2.0g/cm3,电阻率≤8.0μΩm,抗折强度≥25Mpa,抗压强度≥35Mpa,灰分≤0.20%;沥青焦的粒度为1-60μm,真密度≥2.13g/cm3,灰分≤0.25%、含硫量≤0.3%、挥发份≤0.5%;中温煤沥青为软化点为83-89℃,结焦值为≥58%,灰分≤0.30%;所述粘结剂采用酚醛树脂,软化点为105-120℃。
3.根据权利要求1所述的一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于:所述沥青焦的粒度为1-10μm占其重量的10%,粒度为10-20μm占其重量的20%,粒度为20-30μm占其重量的20%,粒度为30-40μm占其重量的20%,粒度为40-50μm占其重量的20%,粒度为50-60μm占其重量的10%;Al2O3的粒度为1-3μm占其重量的20%,粒度为3-5μm占其重量的30%,粒度为5-8μm占其重量的30%,粒度为8-10μm占其重量的20%;ZrO2的粒度为1-5μm占其重量的35%,粒度为5-10μm占其重量的30%,粒度为10-15μm占其重量的35%;SiC的粒度为1-5μm占其重量的15%,粒度为5-10μm占其重量的35%,粒度为10-15μm占其重量的35%,粒度为15-20μm占其重量的15%;Al2O3-SiO2的粒度为1-5μm占其重量的10%,粒度为5-10μm占其重量的20%,粒度为10-15μm占其重量的20%,粒度为15-20μm占其重量的20%,粒度为20-25μm占其重量的20%,粒度为25-30μm占其重量的10%;碳黑的粒度为1-10μm占其重量的25%,粒度为10-20μm占其重量的25%,粒度为20-30μm占其重量的25%,粒度为30-40μm占其重量的25%;特种石墨粉的粒度为1-10μm占其重量的10%,粒度为10-20μm占其重量的20%,粒度为20-30μm占其重量的25%,粒度为30-40μm占其重量的25%,粒度为40-50μm占其重量的20%。
4.根据权利要求1所述的一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于:所述Al2O3、ZrO2、SiC、Al2O3-SiO2、碳黑、特种石墨粉的混合料,其重量比为8:5:12:20:25:30;研磨后混合粉料与沥青焦重量比为40:60;混捏后混合粉料与粘结剂重量比为70:30-75:25。
5.根据权利要求1所述的一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于:所述S5中焙烧的升温程序为:焙烧温度为20℃-1250℃,室温-100℃,按照100℃/h升温,保持1h;100-200℃,按照100℃/h升温,保持1h;200℃-900℃、按照100℃/h升温,保持7h;900℃-1250℃、按照按照150℃/h升温,保持2h;并在1250℃温度下保温4h,然后自然冷却。
6.根据权利要求1所述的一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于:所述S6中温沥青在加入前进行融化,在预热炉中坩埚加热的过程当中,准备沥青融化,通电前检查电路、水路是否畅通。
7.根据权利要求1所述的一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于:所述S7二次焙烧前,利用烘干设备对浸渍处理后的烧结碳滑条材料初坯进行烘干处理。
8.根据权利要求1所述的一种Al2O3-ZrO2碳滑板材料制备方法,其特征在于:所制备的Al2O3-ZrO2碳滑板制备方法,其体积密度≤4g/cm3、抗折强度≥80、抗压强度≥160、冲击韧性≥0.2J/cm2、20℃电阻率≤10µΩ·m、洛氏硬度≤100。
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