CN112851390A - 铸钢用三维网络多孔陶瓷及其制备方法 - Google Patents

铸钢用三维网络多孔陶瓷及其制备方法 Download PDF

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CN112851390A
CN112851390A CN202110087967.8A CN202110087967A CN112851390A CN 112851390 A CN112851390 A CN 112851390A CN 202110087967 A CN202110087967 A CN 202110087967A CN 112851390 A CN112851390 A CN 112851390A
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李世慧
王安英
孙传兵
孟姗姗
于修水
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Shandong Sicer Novel Material Co ltd
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Abstract

本发明属于陶瓷材料技术领域，具体涉及一种铸钢用三维网络多孔陶瓷及其制备方法。所述的铸钢用三维网络多孔陶瓷，以废弃粉煤灰为主要原料，将其与片状氧化铝、γ氧化铝、水和粘合剂混合成型后，经结构叠层设计得到。本发明采用价格低廉的粉煤灰为主要原料，大大节约了生产成本；通过结构叠层设计得到三维网络多孔结构陶瓷过滤器，孔径可控，无需聚氨酯海绵为载体，是一种绿色制备方式，环保安全，在使用过程中也更加的安全可靠。本发明的制备方法，通过压制或挤压后的结构，形成结构功能一体化的三维网络通孔陶瓷，工艺简单，能够满足大批量生产。比起近几年兴起的3D打印更具成本和效益优势，具有明显的创新和经济意义。

Description

铸钢用三维网络多孔陶瓷及其制备方法
技术领域
本发明属于陶瓷材料技术领域，具体涉及一种铸钢用三维网络多孔陶瓷及其制备方法。
背景技术
泡沫陶瓷过滤器是一种气孔率高达70～90％的具有三维立体网络骨架和相互贯通气孔结构的多孔陶瓷制品，由于其具有耐高温、耐腐蚀、气孔率高、比表面积大、密度小、对流体自扰性强等特点，所以广泛应用于耐高温环境下的流体过滤净化、催化剂载体等领域。其用于金属液过滤净化，可高效率的去除金属液中大块的夹杂物和大部分小至微米的微小悬浮夹杂物，并促进部分气体的析出，从而大大降低铸件废品率，提高铸件质量和成品率，降低生产成本，提高生产效率。在铸钢时，由于钢液的温度高达1600℃以上，其使用的泡沫陶瓷过滤器目前普遍采用氧化镁稳定氧化锆来制备。
中国专利CN200710115193.5公开了一种氧化锆材质泡沫陶瓷的制备方法，主要以氧化锆添加少量或部分稳定剂为原料来制备氧化锆材质泡沫陶瓷过滤器，其优势是为了降低成本采用了单晶氧化锆。通过加入稳定剂及少量添加剂制备氧化锆泡沫陶瓷是目前普遍的方式，但是制备的氧化锆泡沫陶瓷往往由于高温晶型转变导致力学性能衰减，抗侵蚀能力也降低，导致在一些高温下需要长期使用的场合，产品往往失效。
目前市场上铸钢用泡沫陶瓷过滤器普遍采用氧化锆等为主要原料，采用聚氨酯作为载体，附着浆料后高温烧制而成，这种制备工艺：一是所用原料价格高，二是需要聚氨酯海绵为载体，排胶过程中不仅对环境造成影响而且孔径的大小也受制于聚氨酯海绵的孔径大小，在一些特殊领域不能满足要求。美国ASK公司通过3D打印技术制备孔径可控的泡沫陶瓷过滤器来解决这一问题，但是3d打印效率极低，不能满足批量生产，另外需要较高的设备及技术支持。
发明内容
针对现有技术的不足，本发明的目的是提供一种铸钢用三维网络多孔陶瓷，采用价格低廉的粉煤灰为主要原料，通过结构叠层设计得到三维网络多孔结构陶瓷过滤器，生产成本低廉，孔径可控，无需聚氨酯海绵为载体，环保安全，在使用过程中也更加的安全可靠。
本发明还提供其制备方法，工艺简单，能够满足大批量生产。
本发明所述的铸钢用三维网络多孔陶瓷，以废弃粉煤灰为主要原料，将其与片状氧化铝、γ氧化铝、水和粘合剂混合成型后，经结构叠层设计得到。
本发明所述的铸钢用三维网络多孔陶瓷的制备方法，包括以下步骤：
(1)将废弃粉煤灰、片状氧化铝、γ氧化铝、水和粘合剂进行球磨混料，得到浆料A；其中，浆料A由以下重量百分数的原料制成：
Figure BDA0002911425060000021
(2)将浆料A除铁后，进行雾化干燥，得到陶瓷混合粉体B；
(3)将陶瓷混合粉体B按照设计好的结构和模具进行干压成型，制备不同单层网络结构，干燥；
(4)将单层网络结构进行角度旋转后，用浆料A进行粘合；或者将不同单层，用浆料A进行粘合；形成多层网络三维结构体，干燥后烧成。
其中：
所述的废弃粉煤灰粒度为200目及以下。
所述的粘合剂为PVA或CMC中的一种或两种。
所述的陶瓷混合粉体B的粒度在130微米以上。
所述的单层网络结构为平面或者设计凹凸单层，带有封边，孔径大小可调，为5-10mm。
所述的烧成温度为1560-1650℃。
与现有技术相比，本发明的有益效果如下：
1、本发明所述的铸钢用三维网络多孔陶瓷，采用价格低廉的粉煤灰为主要原料，大大节约了生产成本。
2、本发明通过结构叠层设计得到三维网络多孔结构陶瓷过滤器，孔径可控，无需聚氨酯海绵为载体，是一种绿色制备方式，环保安全，在使用过程中也更加的安全可靠。
3、本发明的制备方法，通过压制或挤压后的结构，形成结构功能一体化的三维网络通孔陶瓷，工艺简单，能够满足大批量生产。比起近几年兴起的3D打印更具成本和效益优势，具有明显的创新和经济意义。
具体实施方式
以下结合实施例对本发明做进一步说明，但本发明的保护范围不仅限于此，该领域专业人员对本发明技术方案所作的改变，均应属于本发明的保护范围内。
以下实施例中，所述方法如无特别说明均为常规方法，所述原材料如无特别说明均能从公开商业途径而得。
实施例1
粉煤灰200目700g、片状氧化铝10微米100g、γ氧化铝100g、水300g，PVA10g，进行球磨混料制备浆料A，得到的浆料A除铁后，进行喷雾干燥后得到混合后的陶瓷粉料B。通过干压成型制备圆形直径70mm，厚度6mm，具有六边形孔径10mm单层多孔陶瓷结构体C，通过角度旋转60度，将单层结构体用浆料A进行粘合，得到4层的多孔陶瓷过滤体，干燥后，在1560度下烧制2h，得到4层网络三维结构体。经测试，气孔率76.5％；抗压强度15.5MPa；1200度水冷后，抗折强度平均保持率71％。
实施例2
粉煤灰200目600g、片状氧化铝10微米200g、γ氧化铝50g、水200g，PVA5g，CMC10g，进行球磨混料制备浆料A，得到的浆料A除铁后，进行喷雾干燥后得到混合后的陶瓷粉料B。通过干压成型制备方形边长75mm，厚度5mm，孔径为六边形的12mm单层多孔陶瓷结构体C和孔径为正方形的6mm单层多孔陶瓷结构体D，将单层结构体按照CDCD叠构，用浆料A进行粘合，得到4层的多孔陶瓷过滤体，干燥后，在1650度下烧制2h，得到4层网络三维结构体。经测试，气孔率75.2％；抗压强度16MPa；1200度水冷后，抗折强度平均保持率69％。
对比例1
粉煤灰200目600g、煅烧α氧化铝10微米200g、γ氧化铝50g、水200g，PVA5g，CMC10g，进行球磨混料制备浆料A，得到的浆料A除铁后，进行喷雾干燥后得到混合后的陶瓷粉料B。通过干压成型制备方形边长75mm，厚度5mm，孔径为六边形的12mm单层多孔陶瓷结构体C和孔径为正方形的6mm单层多孔陶瓷结构体D，将单层结构体按照CDCD叠构，用浆料A进行粘合，得到4层的多孔陶瓷过滤体，干燥后，在1650度下烧制2h，得到4层网络三维结构体。经测试，气孔率75.3％；抗压强度13.9MPa；1200度水冷后，抗折强度平均保持率52％。
本发明可以自由设计孔径大小，不受聚氨酯载体的限制，同时经济环保，对比3D打印，又具备批量性和经济性，同时对比实施例2和对比例1可以明显看出片状氧化铝的引入，提高了材料的力学性能和抗热震性能。

Claims (7)

1.一种铸钢用三维网络多孔陶瓷，其特征在于：以废弃粉煤灰为主要原料，将其与片状氧化铝、γ氧化铝、水和粘合剂混合成型后，经结构叠层设计得到。
2.一种权利要求1所述的铸钢用三维网络多孔陶瓷的制备方法，其特征在于：包括以下步骤：
(1)将废弃粉煤灰、片状氧化铝、γ氧化铝、水和粘合剂进行球磨混料，得到浆料A；其中，浆料A由以下重量百分数的原料制成：
Figure FDA0002911425050000011
(2)将浆料A除铁后，进行雾化干燥，得到陶瓷混合粉体B；
(3)将陶瓷混合粉体B按照设计好的结构和模具进行干压成型，制备不同单层网络结构，干燥；
(4)将单层网络结构进行角度旋转后，用浆料A进行粘合；或者将不同单层，用浆料A进行粘合；形成多层网络三维结构体，干燥后烧成。
3.根据权利要求2所述的铸钢用三维网络多孔陶瓷的制备方法，其特征在于：所述的废弃粉煤灰粒度为200目及以下。
4.根据权利要求2所述的铸钢用三维网络多孔陶瓷的制备方法，其特征在于：所述的粘合剂为PVA或CMC中的一种或两种。
5.根据权利要求2所述的铸钢用三维网络多孔陶瓷的制备方法，其特征在于：所述的陶瓷混合粉体B的粒度在130微米以上。
6.根据权利要求2所述的铸钢用三维网络多孔陶瓷的制备方法，其特征在于：所述的单层网络结构为平面或者设计凹凸单层，带有封边，孔径大小可调，为5-10mm。
7.根据权利要求2所述的铸钢用三维网络多孔陶瓷的制备方法，其特征在于：所述的烧成温度为1560-1650℃。
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