CN112125684B - 轻质、高强和高抗热震刚玉-莫来石耐火材料的制备方法 - Google Patents

轻质、高强和高抗热震刚玉-莫来石耐火材料的制备方法 Download PDF

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CN112125684B
CN112125684B CN202010991415.5A CN202010991415A CN112125684B CN 112125684 B CN112125684 B CN 112125684B CN 202010991415 A CN202010991415 A CN 202010991415A CN 112125684 B CN112125684 B CN 112125684B
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corundum
mullite
thermal shock
aluminum fluoride
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杨文刚
刘国齐
陈勇强
李红霞
钱凡
于建宾
马渭奎
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Sinosteel Luoyang Institute of Refractories Research Co Ltd
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Abstract

本发明公开了一种轻质、高强和高抗热震的刚玉‑莫来石复合材料及其制备方法，属于耐火材料窑具技术领域。本发明利用不同颗粒级配的刚玉和莫来石、α‑氧化铝微粉、二氧化硅微粉、空心刚玉和氟化铝为原料，通过原料预处理，然后机压成型，空气气氛下1450‑1650℃烧结后，制得刚玉‑莫来石复合材料。本发明利用空心刚玉球提供封闭气孔，提高闭气孔率，减轻材料比重并提高抗热震性。利用氟化铝改变骨料与基质的结合方式，提高刚玉‑莫来石材料的强度和抗热震性。本发明提供的刚玉‑莫来石复合材料对高温窑具的长寿化、轻量化和功能化具有重要意义。

Description

轻质、高强和高抗热震刚玉-莫来石耐火材料的制备方法
技术领域
本发明属于高温窑具技术领域，具体涉及一种轻质、高强和高抗热震刚玉-莫来石耐火材料的制备方法。
背景技术
刚玉-莫来石复合材料因其优异的高温强度、抗热震性和耐化学腐蚀性，并且刚玉、莫来石原料丰富，性价比高，被广泛应用于高温窑具，如刚玉-莫来石匣钵、棚板、推板和陶瓷棍棒等，是高温下抗热震性最好的耐火材料之一。
目前，随着磁性材料、电子陶瓷等新型功能陶瓷的迅速发展，高品质刚玉-莫来石窑具产品需求越来越旺盛。但传统刚玉-莫来石质窑具仍然存在一些问题，如热震稳定性差，服役周期短，高温易受侵蚀等问题，严重影响了企业生产的效率和产品质量的进一步提升。开发具有低蓄热性，使用温度高、高温体积稳定性好、良好的抗热震性以及低蠕变刚玉-莫来石复合材料势在必行。现有的刚玉-莫来石复合材料仍存在高温变形，抗热震性差问题烧结工艺多采用常规烧结，存在烧结周期长、生产效率低、烧结温度高和能源浪费的问题。
发明内容
为解决上述技术问题，本发明的目的是提供一种轻质、高强和高抗热震刚玉-莫来石耐火材料的制备方法。
为了实现以上目的，本发明采用如下技术方案：
一种轻质、高强和高抗热震刚玉-莫来石耐火材料的制备方法，制备方法为由：将电熔莫来石骨料、活性氧化铝微粉、二氧化硅微粉、空心刚玉球与氟化铝包覆的板刚玉混合，成型制成生坯，将生坯置于电炉中，高温烧结，即得；所述的氟化铝包覆的板刚玉采用树脂粘结剂共混法制备，使其能够在碳化硅颗粒外包覆氧化锆即可，具体步骤如下：
1）将氟化铝和板刚玉共同混料30min，然后向混合料中加入热塑性酚醛树脂，混料30 min，80℃干燥后，所述的氟化铝由通过树脂固定在板刚玉表面，形成氟化铝与刚玉的复合骨料；
2）将复合骨料与电熔莫来石骨料、活性氧化铝微粉、二氧化硅微粉和空心刚玉球共混30 min，再加入热塑性酚醛树脂，共混30min，获得混合料；
3）所获混合料含水量在2%～4%，机压成型，成型压力60～100MPa；
4） 烧结工艺为600℃以下升温速度为2～3℃/min，600℃以上设定升温速率为3℃/min；待温度升至1450-1650℃，保温180～240min，随炉降温，即得刚玉-莫来石复合材料。
粒径1-3mm的板刚玉与活性氧化铝微粉、二氧化硅微粉之间存在有氟化铝，混合料中含有粒度为0.1-1 mm的刚玉空心球。
所述刚玉-莫来石复合材料中粒度为1-3mm的莫来石含量5%～15wt%，粒度为0.5-1mm的莫来石含量10%～30wt%，粒度为0.045mm的莫来石含量5%～15wt%，粒度为1-3mm的板状刚玉含量5%～25wt%，粒度为0.5-1mm的板状刚玉含量10%～30wt%，粒度为0.045 mm的板状刚玉含量为5%～15wt%，粒度为2 μm的氧化铝微粉含量为5%～20wt%，二氧化硅=硅微粉为2%～6wt%，刚玉空心球含量10～30wt%，氟化铝含量5～20wt%。
所述氟化铝为纳米级，如< 100 nm。
所述氟化铝包覆的板刚玉中氟化铝的质量分数为5%～20%。
所述成型可采用等静压成型或干压成型等。
所述微波烧结温度在1450-1650℃。
本发明提出的一种轻质、高强和高抗热震刚玉-莫来石耐火材料的制备方法，采用上述技术方案，具有如下有益效果：
普通的刚玉-莫来石耐火材料，由于基质细粉与大颗粒骨料之间很难发生烧结，且细粉易发生烧结收缩，从而在大颗粒与基质之间总会有大量间隙，弱化了材料整体的结合强度；尽管提高烧结温度可改善烧结特性，改善结合强度，但整体发生烧结，导致裂纹极易传播，抗热震性较差；本发明通过在板刚玉骨料表面引入氟化铝，通过高温下氟化铝与刚玉的反应，活化骨料表面，此外，高温反应生成的含铝气相与含氟气相通过气相反应生成莫来石晶须，莫来石晶须在活化的骨料与基质细粉之间生长，改变了骨料与基质的结合方式，极大地改善了刚玉-莫来石复合材料的强度与抗热震性，此外，结合空心刚玉球的引入，降低了材料的比重，提供闭气孔进一步改善了材料的抗热震性。
附图说明
图1为本发明中刚玉-莫来石复合材料中骨料与基质结合的显微结构照片；
图2a、b为本发明刚玉-莫来石复合材料的显微形貌照片；
图3对比例中刚玉-莫来石复合材料中骨料与基质结合的显微结构照片；
图4a、b对比例中刚玉-莫来石复合材料的显微形貌照片图。
具体实施方式
下述实施例仅对本发明作进一步详细说明，但不构成对本发明的任何限制。
实施例：
本实施例中刚玉-莫来石的制备步骤如下：
1）取20g的氟化铝与50ml的酚醛树脂，加入烧杯中，再加入50ml的无水乙醇，机械搅拌30min，再加入50g的板刚玉，继续搅拌30min，得到混合料；
2）取上述混合料，80℃干燥后，获得复合粉料；
3）取上述复合粉料，加入莫来石、氧化铝微粉、二氧化硅微粉与空心刚玉球，采用酚醛树脂做结合剂，共混60min，获得混合料。
4）取混合料机压成型，成型压力60~100MPa。
4） 烧结工艺为600℃以下升温速度为2~3℃/min，600℃以上设定升温速率为3℃/min。待温度升至1450-1650℃，保温180~240min，随炉降温，即得刚玉-莫来石复合材料
所得刚玉-莫来石的气孔率为20-30%，1100℃一次水冷热震后的残余抗折强度在14MPa以上，强度保持率在80%以上。刚玉骨料与基质的结合方式如图1所示，复合材料的整体和局部显微形貌如图2a、b所示。
对比例：
本对比例中刚玉-莫来石的制备步骤如下：
1）取板刚玉、莫来石、氧化铝微粉、二氧化硅微粉与空心刚玉球，采用酚醛树脂做结合剂，共混60min，获得混合料。
2）取混合料机压成型，成型压力60~100MPa。
4） 烧结工艺为600℃以下升温速度为2~3℃/min，600℃以上设定升温速率为3℃/min。待温度升至1450-1650℃，保温180~240min，随炉降温，即得刚玉-莫来石复合材料
所得刚玉-莫来石的气孔率为10-20%，1100℃一次水冷热震后的残余抗折强度在8MPa以上，强度保持率在50%以下。刚玉骨料与基质的结合方式如图3所示，复合材料的整体和局部显微形貌如图4a、b所示。

Claims (7)

1.一种轻质、高强和高抗热震的刚玉-莫来石复合材料的制备方法，其特征在于：将电熔莫来石骨料、活性氧化铝微粉、二氧化硅微粉、空心刚玉球与氟化铝包覆的板状刚玉混合，成型制成生坯，将生坯置于电炉中，高温烧结，即得；所述的氟化铝包覆的板状刚玉采用树脂粘结剂共混法制备，使得板状刚玉颗粒被氟化铝包覆，具体步骤如下：
1）将氟化铝和板状刚玉共同混料30min，然后向混合料中加入热塑性酚醛树脂，混料30min，80℃干燥后，所述的氟化铝由通过树脂固定在板状刚玉表面，形成氟化铝与板状刚玉的复合骨料；
2）将复合骨料与电熔莫来石骨料、活性氧化铝微粉、二氧化硅微粉和空心刚玉球共混30 min，再加入热塑性酚醛树脂，共混30min，获得混合料；
3）所获混合料含水量在2%～4%，机压成型，成型压力60～100MPa；
4） 烧结工艺为600℃以下升温速度为2～3℃/min，600℃以上设定升温速率为3℃/min；待温度升至1450-1650℃，保温180～240min，随炉降温，即得刚玉-莫来石复合材料。
2.如权利要求1所述的一种轻质、高强和高抗热震的刚玉-莫来石复合材料的制备方法，其特征在于：所述刚玉-莫来石复合材料中粒度为1-3mm的电熔莫来石含量5%～15wt%，粒度为0.5-1mm的电熔莫来石含量10%～30wt%，粒度为0.045mm的电熔莫来石含量5%～15wt%，粒度为1-3mm的板状刚玉含量5%～25wt%，粒度为0.5-1mm的板状刚玉含量10%～30wt%，粒度为0.045 mm的板状刚玉含量为5%～15wt%，粒度为2 μm的氧化铝微粉含量为5%～20wt%，二氧化硅微粉为2%～6wt%，刚玉空心球含量10～30wt%，氟化铝含量5～20wt%。
3.如权利要求1所述的一种轻质、高强和高抗热震的刚玉-莫来石复合材料的制备方法，其特征在于：粒径1-3mm的板状刚玉与活性氧化铝微粉、二氧化硅微粉之间存在有氟化铝，混合料中含有粒度为0.1-1 mm的刚玉空心球。
4.如权利要求1所述的一种轻质、高强和高抗热震的刚玉-莫来石复合材料的制备方法，其特征在于：所述氟化铝为纳米级，< 100 nm。
5.如权利要求1所述的一种轻质、高强和高抗热震的刚玉-莫来石复合材料的制备方法，其特征在于：板状刚玉颗粒被纳米氟化铝粉体包覆。
6.如权利要求1所述的一种轻质、高强和高抗热震的刚玉-莫来石复合材料的制备方法，其特征在于：所述成型可采用等静压成型或干压成型。
7.如权利要求1所述的一种轻质、高强和高抗热震的刚玉-莫来石复合材料的制备方法，其特征在于：所述微波烧结温度在1450-1650℃。
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