CN111943686B - 陶瓷支撑体制备方法及金属制品烧结工艺 - Google Patents

陶瓷支撑体制备方法及金属制品烧结工艺 Download PDF

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CN111943686B
CN111943686B CN202010640884.2A CN202010640884A CN111943686B CN 111943686 B CN111943686 B CN 111943686B CN 202010640884 A CN202010640884 A CN 202010640884A CN 111943686 B CN111943686 B CN 111943686B
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ceramic
metal product
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sintering
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CN111943686A (zh
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代喜凤
李阳
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Shenzhen Element Technology Co ltd
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Shenzhen Element Technology Co ltd
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Abstract

本发明公开了陶瓷支撑体制备方法及金属制品烧结工艺，陶瓷支撑体包括陶瓷粉末和塑基黏结剂，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4。通过控制陶瓷粉末与塑基黏结剂的配比使得陶瓷支撑体与金属产品有着相同的固含量、装载量，从而令陶瓷支撑体的烧结收缩率与金属制品的烧结收缩率相同或相近，进而使得陶瓷支撑体能够在金属烧结的过程中发挥优异的固定、支撑金属制品的作用，大幅改善金属制品在烧结过程中的变形现象，提高金属制品的良品率，降低金属制品制造成本。

Description

陶瓷支撑体制备方法及金属制品烧结工艺
技术领域
本发明涉及注射成形技术领域，尤其涉及陶瓷支撑体制备方法及金属制品烧结工艺。
背景技术
金属制品经成形工艺后，生胚在烧结过程易发生变形，造成金属制品不良，特别是烧结后不易整形的件(强度高且塑性一般)及异形件(无法整形)，当发生不良时，只能丢弃，导致金属制品生产成本偏高。
为提高金属制品的良品率，在金属制品生胚烧结的过程中需要使用支撑体对生胚进行支撑，以改善复杂结构的金属制品在烧结过程中出现的变形。但是，目前业内还未找到与金属制品的烧结收缩率相同或相近的支撑体材料，所以，现有的用于金属烧结制程的支撑体在烧结过程中对金属制品的支撑效果往往差强人意。
发明内容
本发明所要解决的技术问题是：提供一种陶瓷支撑体制备方法及金属制品烧结工艺，该陶瓷支撑体能够有效改善金属制品在烧结过程中的变形现象。
为了解决上述技术问题，本发明采用的技术方案一为：陶瓷支撑体，包括陶瓷粉末和塑基黏结剂，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4。
进一步的，所述陶瓷粉末的粒径为1～30μm。
进一步的，所述陶瓷粉末包括SiO2、Al2O3、CaO、CaCO3、MgO、MgCO3、TiO2、ZrO2、ZnO、SnO2、Nb2O5、MnO2、Co2O3、MoO3、BaO和BaCO3中的至少两种。
进一步的，所述塑基黏结剂包括聚乙烯、聚苯烯、硬脂酸、硬脂酸锌、乙烯-醋酸乙烯共聚物、邻苯二甲酸二辛酯、尼龙、石蜡、微晶石蜡和抗氧化剂中的至少一种以及聚甲醛。
进一步的，所述塑基黏结剂中聚甲醛的重量百分比为60～90％。
为了解决上述技术问题，本发明采用的技术方案二为：陶瓷支撑体的制备方法，包括如下步骤，
称重：根据待烧结金属制品的烧结收缩比称取陶瓷粉末及塑基粘结剂，其中，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4；
混合：将称好的粉体混合均匀，得到混合粉体；
混炼预热：将所述混合粉体加入到预热好的混炼机中进行预热，得到陶瓷塑基喂料；
混炼：将预热后的陶瓷塑基喂料在混炼机中混合均匀并结成泥团状以得到混炼泥团；
挤出制粒：将混炼泥团加入至挤出机中，塑化后挤出并造粒，得到待注射成形的喂料；
注射成形：将待注射成形的喂料在注射机中注射成形，得到陶瓷生胚。
进一步的，所述陶瓷粉末的粒径为1～30μm。
为了解决上述技术问题，本发明采用的技术方案三为：金属制品烧结工艺，包括如下步骤，
获取原料：获取金属制品生胚和陶瓷生胚，所述陶瓷生胚通过上述陶瓷支撑体的制备方法制得；
组合：将金属制品生胚与陶瓷生胚进行组装结合，得到组合件；
催化脱脂：对所述组合件进行脱脂；
烧结：将经过催化脱脂后的所述组合件放入烧结炉中进行烧结。
进一步的，烧结步骤后还包括步骤，去除陶瓷：击碎烧结后的陶瓷生胚，清除烧结后的金属制品生胚上的陶瓷残渣。
进一步的，催化脱脂过程在硝酸催化脱脂炉中进行，脱脂温度为100～150℃，硝酸流量为1～10g/min。
本发明的有益效果在于：通过控制陶瓷粉末与塑基黏结剂的配比使得陶瓷支撑体与金属产品有着相同的固含量、装载量，从而令陶瓷支撑体的烧结收缩率与金属制品的烧结收缩率相同或相近，进而使得陶瓷支撑体能够在金属烧结的过程中发挥优异的固定、支撑金属制品的作用，大幅改善金属制品在烧结过程中的变形现象，提高金属制品的良品率，降低金属制品制造成本。
具体实施方式
为详细说明本发明的技术内容、所实现目的及效果，以下结合实施方式予以说明。
陶瓷支撑体，包括陶瓷粉末和塑基黏结剂，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4。
从上述描述可知，本发明的有益效果在于：通过控制陶瓷粉末与塑基黏结剂的配比使得陶瓷支撑体与金属产品有着相同的固含量、装载量，从而令陶瓷支撑体的烧结收缩率与金属制品的烧结收缩率相同或相近，进而使得陶瓷支撑体能够在金属烧结的过程中发挥优异的固定、支撑金属制品的作用，大幅改善金属制品在烧结过程中的变形现象，提高金属制品的良品率，降低金属制品制造成本。
进一步的，所述陶瓷粉末的粒径为1～30μm。
由上述描述可知，金属制品通过金属粉末注射成形，陶瓷粉末的粒径与金属粉末的粒径相同或相近。能够让金属制品烧结收缩率与陶瓷支撑体烧结收缩率更相近。
进一步的，所述陶瓷粉末包括SiO2、Al2O3、CaO、CaCO3、MgO、MgCO3、TiO2、ZrO2、ZnO、SnO2、Nb2O5、MnO2、Co2O3、MoO3、BaO和BaCO3中的至少两种。
由上述描述可知，可采用来源广泛、价格低廉的陶瓷粉末，利于将陶瓷支撑体的制造成本降低。
进一步的，所述塑基黏结剂包括聚乙烯、聚苯烯、硬脂酸、硬脂酸锌、乙烯-醋酸乙烯共聚物、邻苯二甲酸二辛酯、尼龙、石蜡、微晶石蜡和抗氧化剂中的至少一种以及聚甲醛。
进一步的，所述塑基黏结剂中聚甲醛的重量百分比为60～90％。
陶瓷支撑体的制备方法，包括如下步骤，
称重：根据待烧结金属制品的烧结收缩比称取陶瓷粉末及塑基粘结剂，其中，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4；
混合：将称好的粉体混合均匀，得到混合粉体；
混炼预热：将所述混合粉体加入到预热好的混炼机中进行预热，得到陶瓷塑基喂料；
混炼：将预热后的陶瓷塑基喂料在混炼机中混合均匀并结成泥团状以得到混炼泥团；
挤出制粒：将混炼泥团加入至挤出机中，塑化后挤出并造粒，得到待注射成形的喂料；
注射成形：将待注射成形的喂料在注射机中注射成形，得到陶瓷生胚。
由上述描述可知，通过粉末注射成形工艺制备的陶瓷支撑体粉料便宜，成本低廉，且可制备结构复杂的支撑体；通过粉末注射成形工艺制备的陶瓷支撑体与金属制品有着相同的烧结收缩比，彻底消除烧结过程中因自重、曲面弧度大、烧结炉温场不均匀等问题而引起的金属制品变形、收缩不一致等问题。
进一步的，所述陶瓷粉末的粒径为1～30μm。
由上述描述可知，金属制品通过金属粉末注射成形，陶瓷粉末的粒径与金属粉末的粒径相同或相近。能够让金属制品烧结收缩率与陶瓷支撑体烧结收缩率更相近。
金属制品烧结工艺，包括如下步骤，
获取原料：获取金属制品生胚和陶瓷生胚，所述陶瓷生胚通过上述陶瓷支撑体的制备方法制得；
组合：将金属制品生胚与陶瓷生胚进行组装结合，得到组合件；
催化脱脂：对所述组合件进行脱脂；
烧结：将经过催化脱脂后的所述组合件放入烧结炉中进行烧结。
由上述描述可知，将金属制品生胚与陶瓷生胚组装结合后再进行催化脱脂，利于提高生产效率，节约生产资源。
进一步的，烧结步骤后还包括步骤，去除陶瓷：击碎烧结后的陶瓷生胚，清除烧结后的金属制品生胚上的陶瓷残渣。
由上述描述可知，通过粉末注射成形工艺制备的陶瓷支撑体，经过粉末调控，质地较脆，可轻轻敲击碎落，为金属制品保型的同时，易于清理清除。
进一步的，催化脱脂过程在硝酸催化脱脂炉中进行，脱脂温度为100～150℃，硝酸流量为1～10g/min。
实施例一
本发明的实施例一为：陶瓷支撑体，用于在金属制品烧结的过程中支撑金属制品以防金属制品变形，所述金属制品通过金属粉末注射成形工艺制成，陶瓷支撑体包括陶瓷粉末和塑基黏结剂，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4，所述陶瓷粉末的粒径为1～30μm。容易理解的，通过控制陶瓷粉末的粒径(保持陶瓷粉末与金属粉体一致的粒径分布)和塑基黏结剂与陶瓷粉末的质量比，使得陶瓷支撑体与金属制品有着相同的固含量、装载量，这样，陶瓷支撑体的烧结收缩率可以调控到与金属制品的烧结收缩率相同或相近，从而使得陶瓷支撑体在烧结过程中能够对金属制品起到良好的固定、支撑作用。
所述陶瓷粉末包括SiO2(二氧化硅)、Al2O3(三氧化二铝)、CaO(氧化钙)、CaCO3(碳酸钙)、MgO(氧化镁)、MgCO3(碳酸镁)、TiO2(二氧化钛)、ZrO2(二氧化锆)、ZnO(氧化锌)、SnO2(氧化锡)、Nb2O5(五氧化二铌)、MnO2(二氧化锰)、Co2O3(三氧化二钴)、MoO3(三氧化钼)、BaO(氧化钡)和BaCO3(碳酸钡)中的至少两种。
所述塑基黏结剂包括聚乙烯、聚苯烯、硬脂酸、硬脂酸锌、乙烯-醋酸乙烯共聚物、邻苯二甲酸二辛酯、尼龙、石蜡、微晶石蜡和抗氧化剂中的至少一种以及聚甲醛。优选的，所述塑基黏结剂中聚甲醛的重量百分比为60～90％。
实施例二
本发明的实施例二为：金属制品烧结工艺，包括如下步骤，
S1获取原料：获取金属制品生胚和陶瓷生胚；
S2组合：将金属制品生胚与陶瓷生胚进行组装结合，得到组合件；
S3催化脱脂：对所述组合件进行脱脂；具体为，将所述组合件放入硝酸催化脱脂炉中进行脱脂，脱脂温度为100～150℃，硝酸流量为1～10g/min，脱脂时间依据陶瓷生胚形状而定，一般为1mm/h；
S4烧结：将经过催化脱脂后的所述组合件放入烧结炉中进行烧结。
S1获取原料步骤中，所述陶瓷生胚通过陶瓷支撑体的制备方法制得，所述陶瓷支撑体的制备方法包括如下步骤，
S11称重：根据待烧结金属制品(即金属制品生胚)的烧结收缩比称取陶瓷粉末及塑基粘结剂，其中，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4，所述陶瓷粉末的粒径为1～30μm；通过控制陶瓷粉末的粒径(保持陶瓷粉末与金属粉体一致的粒径分布)和塑基黏结剂与陶瓷粉末的质量比，使得陶瓷支撑体与金属制品有着相同的固含量、装载量，这样，陶瓷支撑体的烧结收缩率可以调控到与金属制品的烧结收缩率相同或相近。
S12混合：将称好的粉体通过V型球磨机混合均匀，得到混合粉体；
S13混炼预热：将所述混合粉体加入到预热好的混炼机中进行预热，得到陶瓷塑基喂料，其中，预热温度不低于130℃，预热过程混炼机转速为2～15r/min，预热时间为30～120min；
S14混炼：将预热后的陶瓷塑基喂料在混炼机中混合，使陶瓷粉末和塑基黏结剂均匀混合并结成泥团状以得到混炼泥团，其中，混炼温度为150～200℃，混炼机转速20～60r/min；混炼时间为20～120min；
S15挤出制粒：将混炼泥团加入至挤出机中，塑化后挤出并造粒，得到待注射成形的喂料；
S16注射成形：将经S15挤出制粒步骤得到的待注射成形的喂料在注射机中注射成形，得到金属制品生胚烧结所需的陶瓷生胚，其中，注射温度为170～200℃，保压压力为40～100MPa。
进一步的，所述陶瓷粉末包括SiO2(二氧化硅)、Al2O3(三氧化二铝)、CaO(氧化钙)、CaCO3(碳酸钙)、MgO(氧化镁)、MgCO3(碳酸镁)、TiO2(二氧化钛)、ZrO2(二氧化锆)、ZnO(氧化锌)、SnO2(氧化锡)、Nb2O5(五氧化二铌)、MnO2(二氧化锰)、Co2O3(三氧化二钴)、MoO3(三氧化钼)、BaO(氧化钡)和BaCO3(碳酸钡)中的至少两种。
所述塑基黏结剂包括聚乙烯、聚苯烯、硬脂酸、硬脂酸锌、乙烯-醋酸乙烯共聚物、邻苯二甲酸二辛酯、尼龙、石蜡、微晶石蜡和抗氧化剂中的至少一种以及聚甲醛。优选的，所述塑基黏结剂中聚甲醛的重量百分比为60～90％。聚甲醛作为填充剂，可调节喂料的流变性能。
S4烧结步骤后还包括步骤，S5去除陶瓷：击碎烧结后的陶瓷生胚，清除烧结后的金属制品生胚上的陶瓷残渣。通过粉末注射成形工艺制备的陶瓷支撑体，通过粉末调控，其质地较脆，可轻轻敲击碎落，为金属制品保型的同时，易于清理清除。
综上所述，本发明提供的陶瓷支撑体制备方法及金属制品烧结工艺，陶瓷支撑体的烧结收缩率与金属制品的烧结收缩率相同或相近，大幅改善金属制品在烧结过程中的变形现象，提高金属制品的良品率，降低金属制品制造成本；通过粉末注射成形工艺制备的陶瓷支撑体粉料便宜，成本低廉，且可制备结构复杂的支撑体；通过粉末注射成形工艺制备的陶瓷支撑体与金属制品有着相同的烧结收缩比，彻底消除烧结过程中因自重、曲面弧度大、烧结炉温场不均匀等问题而引起的金属制品变形、收缩不一致等问题。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书内容所作的等同变换，或直接或间接运用在相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (2)

1.陶瓷支撑体的制备方法，其特征在于，包括如下步骤，
称重：根据待烧结金属制品的烧结收缩比称取陶瓷粉末及塑基黏结 剂，其中，所述陶瓷粉末和塑基黏结剂的质量比为6～9:1～4；所述陶瓷粉末的粒径为1～30μm；所述陶瓷粉末包括SiO2、Al2O3、CaO、CaCO3、MgO、MgCO3、TiO2、ZrO2、ZnO、SnO2、Nb2O5、MnO2、Co2O3、MoO3、BaO和BaCO3中的至少两种；所述塑基黏结剂包括聚乙烯、聚苯烯、硬脂酸、硬脂酸锌、乙烯-醋酸乙烯共聚物、邻苯二甲酸二辛酯、尼龙、石蜡、微晶石蜡和抗氧化剂中的至少一种以及聚甲醛；所述塑基黏结剂中聚甲醛的重量百分比为60～90％；
混合：将称好的粉体混合均匀，得到混合粉体；
混炼预热：将所述混合粉体加入到预热好的混炼机中进行预热，得到陶瓷塑基喂料；
混炼：将预热后的陶瓷塑基喂料在混炼机中混合均匀并结成泥团状以得到混炼泥团；
挤出制粒：将混炼泥团加入至挤出机中，塑化后挤出并造粒，得到待注射成形的喂料；
注射成形：将待注射成形的喂料在注射机中注射成形，得到陶瓷生胚。
2.金属制品烧结工艺，其特征在于，包括如下步骤，
获取原料：获取金属制品生胚和陶瓷生胚，所述陶瓷生胚通过权利要求1所述的陶瓷支撑体的制备方法制得；
组合：将金属制品生胚与陶瓷生胚进行组装结合，得到组合件；
催化脱脂：对所述组合件进行脱脂；催化脱脂过程在硝酸催化脱脂炉中进行，脱脂温度为100～150℃，硝酸流量为1～10g/min；
烧结：将经过催化脱脂后的所述组合件放入烧结炉中进行烧结；
去除陶瓷：击碎烧结后的陶瓷生胚，清除烧结后的金属制品生胚上的陶瓷残渣。
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