CN111892392A - 一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法 - Google Patents
一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法 Download PDFInfo
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Abstract
本发明公开了一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,分别以莫来石颗粒为骨料、Al2O3为细粉和Isobam为凝固成型剂,采用浇注成型技术净近尺寸制备重型燃气轮机用耐火隔热瓦。该法在坯体成型‑干燥‑烧结的过程中,材料几乎没有线变化,实现了复杂形状耐火隔热瓦的净近尺寸成型;同时材料选用刚玉‑莫来石体系,制备过程无杂质引入,材料具有纯度高、耐高温、抗热震和力学性能优异等特性。
Description
技术领域
本发明涉及浇注料技术领域,尤其涉及一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法。
背景技术
重型燃气轮机被誉为装备制造业“皇冠上的明珠”,是迄今为止效率最高的热-功转换类发电设备,是发电和驱动领域的核心设备,关乎国家能源安全、国防安全和工业竞争。几十年来,随着工业技术的发展,为追求更高的燃气轮机的热效率,燃气轮机燃烧室的温度不断提高,燃烧室的温度已经从最初的1000 ℃不到,提高到1600 ℃以上。在这种异常恶劣服役环境(高温、高压、冲击、热梯度等),传统的高温合金已经不能满足需求。在燃烧室近火层,安装耐火隔热瓦被认为是目前最切实可行的办法。刚玉-莫来石质耐火隔热瓦具有耐高温、抗热震、不氧化的特性,在该极端服役环境下不易发生开裂、脱粘,对金属基底起到了很好的保护作用。
目前,刚玉-莫来石质耐火隔热瓦,多采用机压成型或浇注成型。机压成型法,只能制备简单形状的制品,对于复杂形状的材料,多由大量简单形状制品拼接而成,材料成型过程需要大量模具,工序复杂;而且干法成型坯体结构的均匀性远较差;传统的浇注成型方法,多以水泥等无机物作为结合剂,结合剂中的物质可能作为杂质与浇注料中其他成分发生反应而影响其使用性能。如水泥结合剂中的氧化钙在高温下与材料中氧化铝和莫来石等组分反应形成低熔点相,影响了莫来石浇注料的高温性能。
目前,两种刚玉-莫来石质耐火隔热瓦制备方法分别存在如下问题:机压法,材料存在制备工序复杂,坯体均匀性差;浇注法,容易引入杂质影响材料的高温性能。由于以上问题的存在,限制了刚玉-莫来石质耐火隔热瓦更好推广应用。
发明内容
为解决上述技术问题,本发明的目的是提出一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法。
本发明为完成上述目的采用如下技术方案:
一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,耐火隔热瓦浇注料的组成及重量份为:莫来石骨料58~75份,Al2O3细粉25~42份,外加0.3~1份的凝固成型剂Isobam和3~7份的水;将各组分按配比称重并在强制搅拌机内混合均匀,倒入模具中,室温养护3 d,110 ℃保温24 h, 脱模后烧结。
所述的莫来石骨料的组成及重量份为;莫来石粗骨料65~85份,莫来石中骨料5-15份,莫来石细骨料10~25份。
所述莫来石粗骨料的粒径为3~5 mm,莫来石中骨料的粒径为1~3 mm,莫来石细骨料的粒径大于0小于1mm。
所述的 Al2O3细粉包括活性Al2O3微粉60~80份和Al2O3亚微粉基质20~40份。
活性Al2O3微粉的粒径为大于0小于10 μm,Al2O3亚微粉大于0小于0.5 μm。
所述的凝固成型剂Isobam(异丁烯与马来酸酐交替共聚物)为Isobam-104、Isobam-600、Isobam-104、Isobam-600-AF或Isobam-104-WS中的一种或多种。
本发明提出的一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,借鉴陶瓷的注凝成型技术,加入的凝固成型剂为Isobam,加入量≤1%,它既可以做结合剂又可以做分散剂或减水剂使用。在混料时高分子化合物Isobam可以起到减水剂或分散剂的作用,让浇注料中的细颗粒分散更容易分散,降低浇注料的加水料。坯体养护时,在Isobam分子与水和Al2O3颗粒的共同作用下坯体发生一个类“絮凝”的凝固过程。该法便于制备复杂形状的中心燃气轮机隔热瓦,且所制备的刚玉-莫来石材料具有纯度高、耐高温、抗热震、力学性能优异等特点。
具体实施方式
实施例一:
该重型燃气轮机用复杂形状耐火隔热瓦材料的浇注料,组分按重量份包括:骨料70份、细粉30份、外加水4份、Isobam-104外加0.5份。
骨料中,3~5 mm的莫来石粗骨料46份、1~3 mm的莫来石中骨料15份、0~1 mm的细骨料39份。
细粉中,0~10 μm 的Al2O3微粉60份,0~0.5 μm 的Al2O3微亚微粉40份。
将各组分按配比称重并在强制搅拌机内混合均匀,倒入模具中,室温养护3 d,110℃保温24 h, 脱模后1680 ℃保温4 h。
实施例二:
该重型燃气轮机用复杂形状耐火隔热瓦材料的浇注料,组分按重量份包括:骨料65份、细粉35份、外加水6份、Isobam-104 和Isobam-600各外加0.3份。
骨料中,3~5 mm的莫来石粗骨料46份、1~3 mm的莫来石中骨料15份、0~1 mm的细骨料39份。
细粉中,0~10 μm 的Al2O3微粉70份,0~0.5 μm 的Al2O3微亚微粉30份。
将各组分按配比称重并在强制搅拌机内混合均匀,将各组分按配比称重并在强制搅拌机内混合均匀,倒入模具中,室温养护3 d,110 ℃保温24 h, 脱模后1700 ℃保温4 h。
实施例三:
该重型燃气轮机用复杂形状耐火隔热瓦材料的浇注料,组分按重量份包括:骨料60份、细粉40份、外加水5份、Isobam-104外加0.5份。
骨料中,3~5 mm的莫来石粗骨料40份、1~3 mm的莫来石中骨料15份、0~1 mm的细骨料45份。
细粉中,0~10 μm 的Al2O3微粉30份,0~0.5 μm 的Al2O3微亚微粉70份。 将各组分按配比称重并在强制搅拌机内混合均匀,将各组分按配比称重并在强制搅拌机内混合均匀,倒入模具中,室温养护3 d,110 ℃保温24 h, 脱模后1710 ℃保温4 h。
实施例四:
该重型燃气轮机用复杂形状耐火隔热瓦材料的浇注料,组分按重量份包括: 骨料75份、细粉25份、外加水4份、Isobam-600外加0.4份。
骨料中,3~5 mm的莫来石粗骨料40份、1~3 mm的莫来石中骨料15份、0~1 mm的细骨料45份。
细粉中,0~10 μm 的Al2O3微粉55份,0~0.5 μm 的Al2O3微亚微粉45份。
将各组分按配比称重并在强制搅拌机内混合均匀,将各组分按配比称重并在强制搅拌机内混合均匀,倒入模具中,室温养护3 d,110 ℃保温24 h, 脱模后1710 ℃保温4 h。
实施例五:
该重型燃气轮机用复杂形状耐火隔热瓦材料的浇注料,组分按重量份包括:
骨料73份、细粉27份、外加水4.5份、Isobam-600 0.4份。骨料中,3~5mm的莫来石粗骨料45份、1~3 mm的莫来石中骨料14份、0~1 mm的细骨料41份。
细粉中,0~10 μm 的Al2O3微粉65份,0~0.5 μm 的Al2O3微亚微粉35份。
将各组分按配比称重并在强制搅拌机内混合均匀,将各组分按配比称重并在强制搅拌机内混合均匀,倒入模具中,室温养护3 d,110 ℃保温24 h, 脱模后1680 ℃保温6 h。
按照实例一所述制备方案,浇注40 mm×40 mm×150 mm样条,室温养护3 d时后脱模,放入烘箱110 ℃保温24 h,将烘干的样条经1680 ℃保温4 h处理得到烧结好的样块,将样块经1400 ℃风冷热震20次。测试不同温度处理后试样的显气孔率、体积密度、常温抗折和耐压强度(各处理温度相对脱模后的长度变化),测试值见表1.
Claims (6)
1.一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,其特征在于:耐火隔热瓦浇注料的组成及重量份为:莫来石骨料58~75份,Al2O3细粉25~42份,外加0.3~1份的凝固成型剂Isobam和3~7份的水;将各组分按配比称重并在强制搅拌机内混合均匀,倒入模具中,室温养护3 d,110 ℃保温24 h, 脱模后烧结。
2.如权利要求1所述的一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,其特征在于:所述的莫来石骨料的组成及重量份为;莫来石粗骨料65~85份,莫来石中骨料5-15份,莫来石细骨料10~25份。
3.如权利要求1所述的一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,其特征在于:所述莫来石粗骨料的粒径为3~5 mm,莫来石中骨料的粒径为1~3 mm,莫来石细骨料的粒径大于0小于1mm。
4.如权利要求1所述的一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,其特征在于:所述的 Al2O3细粉包括活性Al2O3微粉60~80份和Al2O3亚微粉基质20~40份。
5.如权利要求1所述的一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,其特征在于:活性Al2O3微粉的粒径为大于0小于10 μm,Al2O3亚微粉大于0小于0.5 μm。
6.如权利要求1所述的一种重型燃气轮机用复杂形状耐火隔热瓦的制备方法,其特征在于:所述的凝固成型剂Isobam为Isobam-104、Isobam-600、Isobam-104、Isobam-600-AF或Isobam-104-WS中的一种或多种。
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