CN111875384A - 一种无缝钢管热穿孔用碳化硅顶头的制备方法 - Google Patents
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Abstract
本发明属于无缝钢管生产领域,具体涉及一种无缝钢管热穿孔用碳化硅顶头的制备方法。其制备过程可按如下步骤实现:以两种不同粒度的碳化硅粉为主要原料,以去离子水为球磨介质,以聚乙烯醇(PVA)为粘结剂。将上述原料与碳化硅磨球一起在辊式球磨机中混合均匀,将去离子水蒸发后,研磨过筛得到混合粉体;将混合好的粉体置于不锈钢模具中,以一定压力干压成型,脱模后得到顶头坯体;将脱模后的坯体置于高温烧结炉中进行烧结,得到碳化硅顶头。与既有的结构钢、钼基顶头相比,本发明所提供的碳化硅顶头具有高温强度高、寿命长、价格低等特点。
Description
技术领域
本发明属于无缝钢管生产领域,涉及一种无缝钢管热穿孔用碳化硅顶头的制备方法。
背景技术
无缝钢管是我国国民经济中的重要产品,已经广泛应用于化工、能源、建筑、汽车及国防等众多的工业领域。目前,无缝钢管主要依靠顶头材料进行热穿孔成形。穿孔顶头的服役环境苛刻,工作温度为1000℃左右,同时要承受巨大的径向摩擦、轴向扭矩、热应力、高温氧化等。因此,穿孔顶头的质量、寿命对无缝钢管的质量、生产效率以及工厂的效益都有重要影响。
多年来,穿孔顶头在无缝钢管生产领域受到了广泛关注和研究。目前,我国应用较多的顶头材料主要以结构钢、钼合金等为主要成分。其中,结构钢顶头价格低廉,但在穿孔轧制过程中易出现熔损、热粘或“塌鼻”等现象。尽管开展了很多改进工作,如添加Cr、Ni、Mn、W、Ce等各种合金元素(ZL201410323618.1,ZL200910000886.9)、在穿孔顶头表面被覆氧化物层(ZL201380046791.5)等,但是仍然难以彻底避免其长期服役时的损毁。钼合金顶头性能优异,但其一方面占用战略资源,另一方面价格较高,给用户带来成本增加。另外,在每一根无缝钢管的穿孔轧制过程中,由于毛管的热量和摩擦产生的热量都会导致穿孔后期顶头材料发热严重,高温强度降低,被迫中止轧制过程,对顶头冷却降温后再进行下一个轧制过程。因此,一般所制备无缝钢管长度在6-9米,效率低;因此,需要研制一种低成本的顶头材料,并满足热穿孔轧制过程对顶头材料高温强度、抗热震、抗氧化等要求。
发明内容
为解决上述技术问题,本发明的目的是提出一种无缝钢管热穿孔用碳化硅顶头的制备方法。
本发明为完成上述目的采用如下技术方案:
一种无缝钢管热穿孔用碳化硅顶头的制备方法,制备方法包括混料造粒、顶头坯体的成型、顶头坯体的烧结,其具体工艺步骤为:
1)混料造粒:
以两种不同粒度的碳化硅粉为主要原料,以去离子水为球磨介质,以聚乙烯醇为粘结剂;将加入有去离子水和PVA的碳化硅粉与碳化硅研磨球一起在辊式球磨机中混合均匀,将去离子水蒸发后,研磨过筛得到混合粉体;
所述碳化硅粉的纯度>98%,粗碳化硅粉平均粒径为5~10μm,细碳化硅粉平均粒径为0.5~1μm;
所述的粗碳化硅粉占碳化硅粉的重量比为60~90%,聚乙烯醇的加入量为碳化硅粉总质量的0.1~0.5%;
2)顶头坯体的成型:
将混合好的粉体置于不锈钢模具中,以一定压力干压成型,脱模后得到顶头坯体;
所述的干压成型压力为10~40MPa。
3)顶头坯体的烧结:
将脱模后的坯体置于高温烧结炉中进行烧结,得到碳化硅顶头。
所述的去离子水加入量为碳化硅粉的1~3倍,碳化硅研磨球加入量为碳化硅粉的1~3倍。
所述的烧结过程是在真空或Ar气氛保护下进行的,烧结温度为1800~2000°C,保温1~3h。
本发明提出的一种无缝钢管热穿孔用碳化硅顶头及制备方法,利用碳化硅陶瓷本身抗热震性、抗氧化性优异,高温强度高的特点,结合粉体颗粒级配与无压烧结工艺,提出了一种全新方案;与既有的结构钢、钼基顶头相比,本发明所提供的碳化硅顶头具有高温强度高、寿命长、价格低等特点。
具体实施方式
结合具体实施例对本发明加以说明:
实施例1:
将平均粒径为5μm碳化硅粉60g,平均粒径为0.5μm的碳化硅粉40g,PVA0.5g,以100g去离子水为球磨介质,将上述原料与200g碳化硅研磨球一起在辊式球磨机中球磨混合,将水分蒸发后,再进行研磨过筛,得到混合粉体;将混合粉体在不锈钢模具中干压成型,成型压力为10MPa;将脱模后的坯体置于高温烧结炉中,在真空保护下升温至1800°C,保温3h。制得的碳化硅顶头的相对密度为83.8%,抗折强度为405MPa。
实施例2:
将平均粒径为7μm碳化硅粉90g,平均粒径为0.8μm的碳化硅粉10g,PVA0.3g,以200g去离子水为球磨介质,将上述原料与300g碳化硅研磨球一起在辊式球磨机中球磨混合,将水分蒸发后,再进行研磨过筛,得到混合粉体;将混合粉体在不锈钢模具中干压成型,成型压力为30MPa;将脱模后的坯体置于高温烧结炉中,在Ar保护下升温至1900°C,保温2h。制得的碳化硅顶头的相对密度为80.2%,抗折强度为375MPa。
实施例3:
将平均粒径为10μm碳化硅粉70g,平均粒径为1μm的碳化硅粉30g,PVA0.1g,以300g去离子水为球磨介质,将上述原料与250g碳化硅研磨球一起在辊式球磨机中球磨混合,将水分蒸发后,再进行研磨过筛,得到混合粉体;将混合粉体在不锈钢模具中干压成型,成型压力为40MPa;将脱模后的坯体置于高温烧结炉中,在真空保护下升温至2000°C,保温1h。制得的碳化硅顶头的相对密度为84.3%,抗折强度为411MPa。
实施例4:
将平均粒径为6μm碳化硅粉80g,平均粒径为0.6μm的碳化硅粉20g,PVA0.4g,以100g去离子水为球磨介质,将上述原料与100g碳化硅研磨球一起在辊式球磨机中球磨混合,将水分蒸发后,再进行研磨过筛,得到混合粉体;将混合粉体在不锈钢模具中干压成型,成型压力为20MPa;将脱模后的坯体置于高温烧结炉中,在Ar保护下升温至1900°C,保温2h。制得的碳化硅顶头的相对密度为81.7%,抗折强度为391MPa。
Claims (6)
1.一种无缝钢管热穿孔用碳化硅顶头的制备方法,其特征在于:无缝钢管热穿孔用顶头为碳化硅材质,制备方法包括混料造粒、顶头坯体的成型、顶头坯体的烧结,其具体工艺步骤为:
1)混料造粒:
以两种不同粒度的碳化硅粉为主要原料,以去离子水为球磨介质,以聚乙烯醇为粘结剂;将加入有去离子水和PVA的碳化硅粉与碳化硅研磨球一起在辊式球磨机中混合均匀,将去离子水蒸发后,研磨过筛得到混合粉体;
2)顶头坯体的成型:
将混合好的粉体置于不锈钢模具中,以一定压力干压成型,脱模后得到顶头坯体;
3)顶头坯体的烧结:
将脱模后的坯体置于高温烧结炉中进行烧结,得到碳化硅顶头。
2.如权利要求1所述的一种无缝钢管热穿孔用碳化硅顶头的制备方法,其特征在于:所述碳化硅粉的纯度>98%,粗碳化硅粉平均粒径为5~10μm,细碳化硅粉平均粒径为0.5~1μm。
3.如权利要求1所述的一种无缝钢管热穿孔用碳化硅顶头的制备方法,其特征在于:所述的粗碳化硅粉占碳化硅粉的重量比为60~90%,PVA加入量为碳化硅粉总质量的0.1~0.5%。
4.如权利要求1所述的一种无缝钢管热穿孔用碳化硅顶头的制备方法,其特征在于:所述的去离子水加入量为碳化硅粉的1~3倍,碳化硅研磨球加入量为碳化硅粉的1~3倍。
5.如权利要求1所述的一种无缝钢管热穿孔用碳化硅顶头的制备方法,其特征在于所述的干压成型压力为10~40MPa。
6.如权利要求1所述的一种无缝钢管热穿孔用碳化硅顶头的制备方法,其特征在于:所述的烧结过程是在真空或Ar气氛保护下进行的,烧结温度为1800~2000°C,保温1~3h。
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