CN112960967A - 利用废弃陶粒砂制备的3d打印用陶粒砂及其制备方法 - Google Patents
利用废弃陶粒砂制备的3d打印用陶粒砂及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种利用废弃陶粒砂制备的3D打印用陶粒砂及其制备方法,以废陶粒、含铝矿石、含硅废料作为原料,溶液中的硅酸钠可作为粘结剂,通过喷雾促进材料之间黏连形成规则的球形,同时,加入氢氧化钠和硅酸钠,为混合材料提供碱性环境,打破物料中的的玻璃体,促使废陶粒砂中的氧化硅,氧化铝等成分发生反应,提高产品强度。首先在500℃下预烧,然后在1200℃高温下烧结,各有效成分之间迅速反应结晶,形成晶体结构完善的陶粒砂,增加产品的力学性能和耐火性能。本发明实现多种工矿废料的再生利用,制备工艺简单,节能环保,降低了陶粒砂的成本。制备所得的陶粒砂结构均匀、密实度高、形态完整、力学性能优异、耐高温及耐腐蚀性强。
Description
技术领域
本发明涉及陶粒砂制备技术领域,具体地,涉及一种利用废弃陶粒砂制备的3D打印用陶粒砂及其制备方法。
背景技术
3D打印是一种或几种以数字模型文件为基础,运用粉末状金属或塑料等可粘合材料,通过逐层打印的方式来构造物体的技术。3D打印过程中材料容易破碎产生粉尘等微小颗粒,容易将3D打印机的打印头堵塞,从而导致打印头寿命变短,增加了设备维护成本,3D打印材料的研发和突破是3D打印技术推广应用的基础,也是满足打印的根本保障。
陶粒砂是一种或几种以莫来石相为主的耐火材料,由于其在铸造方面表现出的优良的高温稳定性、良好的流动性、细颗粒物含量低、角形系数低的特点,能够在铸造中替代硅砂。但是,由于陶粒砂存在成本高、浪费大等问题,制约了其在铸造3D打印技术中的应用与发展。因此,在某种程度上,陶粒砂作为3D打印技术发展的重要基础材料,对其进行循环利用决定其在3D打印技术中能否有更广阔的应用。
近年来对废砂及铝土矿作为原材料制备陶粒砂的技术研究越来越多,废砂循环利用技术能有效利用废砂这种固体废弃物、减轻环境压力。但是现有技术中利用废砂制备陶粒砂过程中,高温焙烧环节多、焙烧时间长,能源耗费严重,同时化学试剂及其他辅助原料使用较多且制备工艺繁琐,因此,在另一种程度上提高了陶粒砂的制备成本,不利于废旧陶粒砂的工业应用。
发明内容
本发明要解决的技术问题在于,提供了一种利用废弃陶粒砂制备3D打印用陶粒砂的方法,解决3D打印用砂成本高、循环利用能耗严重、辅料多及工艺繁琐的问题,解决铸造行业产业化推广受制于砂子限制的问题,使3D打印用砂满足在铸造行业产业化推广的条件。
本发明提供了一种利用废弃陶粒砂制备的3D打印用陶粒砂,其特征在于,陶粒砂包括以下重量份的组分:废陶粒砂50~80份、含铝矿石10~20份、含硅废料10~40份。
本发明还提供了一种利用废弃陶粒砂制备3D打印用陶粒砂的方法,其特征在于,包括以下步骤:
(1)称取以下重量份原料:废陶粒砂50~80份、含铝矿石10~20份、含硅废料10~40份,通过研磨、混料和筛选得到混合粉料A;
(2)按照质量比硅酸钠:氢氧化钠:水=(305~455):(61~91):(100~140)的量,将硅酸钠、氢氧化钠加入水中,充分搅拌溶解形成溶液B;
(3)将溶液B通过喷雾形式加入到混合粉料A中同时造粒得到陶粒砂生球;
(4)将陶粒砂生球置于马弗炉中,先在500℃下烧结30min,然后在1200℃下烧结60min,随炉冷却后进行筛分,得到不同粒径区间的陶粒砂。
优选的,步骤(1)中所述研磨过程是在搅拌磨中进行,研磨时间为2h;所述混料过程是在三维混料机中进行,混料时间为3h;所述筛选过程是用200目筛网进行筛选。
优选的,步骤(3)中利用喷雾器将溶液B喷入造粒机中,制备成粒度为20~80目的陶粒砂生球。
优选的,所述废陶粒砂中包括以下质量百分比的组分:SiO2 55%、Al2O3 34%、Fe2O3 7%、MgO 2.5%、CaO 1.5%。
优选的,所述含硅废料为石英砂、粉煤灰中的一种或几种。
本发明的工作原理:本发明中,将废陶粒砂、含铝矿石及含硅废料通过研磨、混料和筛选得到混合粉料,然后将硅酸钠、氢氧化钠混合溶液通过喷雾形式加入到混合粉料造粒得到陶粒砂生球,将陶粒砂生球在500℃下烧结30min,然后在1200℃下烧结60min,随炉冷却后进行筛分,得到不同粒径区间的陶粒砂。其中,以废陶粒砂作为主原料,含铝矿石提供氧化铝,含硅废料补充氧化硅,溶液中的硅酸钠可作为粘结剂,通过喷雾促进材料之间黏连形成规则的球形,同时,加入氢氧化钠和硅酸钠,为混合材料提供碱性环境,打破物料中的的玻璃体,促使废陶粒砂中的氧化硅,氧化铝等成分发生反应,提高产品强度。在500℃下预烧,使得灰分初步分解,同时各有效成分之间进行初步反应,然后在1200℃高温下烧结,各有效成分之间迅速反应结晶,形成晶体结构完善的陶粒砂,增加产品的力学性能和耐火性能。
本发明的有益效果:本发明以废陶粒砂、含铝矿石及含硅废料等工矿废料作为原料制备陶粒砂,实现多种工矿废料的再生利用,制备工艺简单,节能环保,降低了陶粒砂的成本。制备所得的陶粒砂结构均匀、密实度高、形态完整、力学性能优异、耐高温及耐腐蚀性强,在筒压强度为52MPa下陶粒砂破碎率小于15%。
附图说明
图1为废陶粒砂原料的扫描电镜图;
图2为废陶粒砂原料的X射线衍射图谱;
图3为本发明制备所得陶粒砂的X射线衍射图谱1;
图4为本发明制备所得陶粒砂的扫描电镜图1;
图5为本发明制备所得陶粒砂的X射线衍射图谱2;
图6为本发明制备所得陶粒砂的扫描电镜图2;
具体实施方式
为了使本发明技术方案更容易理解,现结合附图采用具体实施例的方式,对本发明的技术方案进行清晰、完整的描述。
实施例1:
本实施例的利用废弃陶粒砂制备的3D打印用陶粒砂,陶粒砂包括以下重量份的组分:废陶粒砂60份、高岭土20份、石英砂20份。
本实施例的利用废弃陶粒砂制备3D打印用陶粒砂的方法,包括以下步骤:
(1)称取以下重量份原料:废陶粒砂60份、高岭土20份、石英砂20份,加入搅拌磨中搅拌2h,然后在三维混料机中混料3h,再用200目筛网过筛得到混合粉料A;
(2)按照质量比硅酸钠:氢氧化钠:水=305:61:100的量,将硅酸钠、氢氧化钠加入水中,充分搅拌溶解形成溶液B;
(3)利用喷雾器将溶液B通过喷雾形式喷入造粒机中,将混合粉料A制备成粒度为20~80目的陶粒砂生球;
(4)将陶粒砂生球置于马弗炉中,先在500℃下烧结30min,然后在1200℃下烧结60min,随炉冷却后进行筛分,得到不同粒径区间的陶粒砂。
所述废陶粒砂中包括以下质量百分比的组分:SiO2 55%、Al2O3 34%、Fe2O3 7%、MgO 2.5%、CaO 1.5%。
实施例2:
本实施例的利用废弃陶粒砂制备的3D打印用陶粒砂,陶粒砂包括以下重量份的组分:废陶粒砂70份、明矾石20份、粉煤灰10份。
本实施例的利用废弃陶粒砂制备3D打印用陶粒砂的方法,包括以下步骤:
(1)称取以下重量份原料:废陶粒砂70份、明矾石20份、粉煤灰10份,加入搅拌磨中搅拌2h,然后在三维混料机中混料3h,再用200目筛网过筛得到混合粉料A;
(2)按照质量比硅酸钠:氢氧化钠:水=400:75:120的量,将硅酸钠、氢氧化钠加入水中,充分搅拌溶解形成溶液B;
(3)利用喷雾器将溶液B通过喷雾形式喷入造粒机中,将混合粉料A制备成粒度为20~80目的陶粒砂生球;
(4)将陶粒砂生球置于马弗炉中,先在500℃下烧结30min,然后在1200℃下烧结60min,随炉冷却后进行筛分,得到不同粒径区间的陶粒砂。
所述废陶粒砂中包括以下质量百分比的组分:SiO2 55%、Al2O3 34%、Fe2O3 7%、MgO 2.5%、CaO 1.5%。
实施例3:
本实施例的利用废弃陶粒砂制备的3D打印用陶粒砂,陶粒砂包括以下重量份的组分:废陶粒砂50份、铝钒土10份、石英砂20份,粉煤灰20份。
本实施例的利用废弃陶粒砂制备3D打印用陶粒砂的方法,包括以下步骤:
(1)称取以下重量份原料:废陶粒砂50份、铝钒土10份、石英砂20份,粉煤灰20份,加入搅拌磨中搅拌2h,然后在三维混料机中混料3h,再用200目筛网过筛得到混合粉料A;
(2)按照质量比硅酸钠:氢氧化钠:水=455:91:140的量,将硅酸钠、氢氧化钠加入水中,充分搅拌溶解形成溶液B;
(3)利用喷雾器将溶液B通过喷雾形式喷入造粒机中,将混合粉料A制备成粒度为20~80目的陶粒砂生球;
(4)将陶粒砂生球置于马弗炉中,先在500℃下烧结30min,然后在1200℃下烧结60min,随炉冷却后进行筛分,得到不同粒径区间的陶粒砂。
所述废陶粒砂中包括以下质量百分比的组分:SiO2 55%、Al2O3 34%、Fe2O3 7%、MgO 2.5%、CaO 1.5%。
对主要原料废陶粒砂进行扫描电镜和X射线衍射图谱表征,得到图1及图2。通过图1可以看出,废陶粒砂中含有大量的玻璃体,主要结晶物相为SiO2、Al2O3、MnO2、Fe2O3;通过图2可以看出,废陶粒砂颗粒尺寸差异较大、分布不均匀,颗粒呈不规则的形态,颗粒表面不光滑且空隙较多。
对本发明制备所得陶粒砂样品进行扫描电镜和X射线衍射图谱表征,得到图3至图6。通过图3及图5可以看出制备的陶粒砂产生Al6Si2O13、Al2SiO5、Fe2Al14Si5O18等结晶物相,表明SiO2、Al2O3和Fe2O3在此工艺下,逐渐发生反应得到结晶物相,逐渐提高了陶粒砂的力学性能和耐火性能;此外还有SiO2、Al2O3和MnO2等物相,这表明体系中成分未能全部参与反应,后续可进一步进行优化;通过图4及图6,可以看出,陶粒砂内部晶粒的轮廓清晰,大小均一,条形状长度约800nm,球形状半径约300nm,呈网状结构,表明样品致密度高,进一步说明通过本发明制备所得陶粒砂结构均匀、密实度高,形态完整。
此外,通过力学性能试验,本发明制备所得陶粒砂样品在筒压强度为52MPa下陶粒砂破碎率小于15%,表现出优异的力学性能。
应当注意,在此所述的实施例仅为本发明的部分实施例,而非本发明的全部实现方式,所述实施例只有示例性,其作用只在于提供理解本发明内容更为直观明了的方式,而不是对本发明所述技术方案的限制。在不脱离本发明构思的前提下,所有本领域普通技术人员没有做出创造性劳动就能想到的其它实施方式,及其它对本发明技术方案的简单替换和各种变化,都属于本发明的保护范围。
Claims (7)
1.一种利用废弃陶粒砂制备的3D打印用陶粒砂,其特征在于,陶粒砂包括以下重量份的组分:废陶粒砂50~80份、含铝矿石10~20份、含硅废料10~40份。
2.一种利用废弃陶粒砂制备3D打印用陶粒砂的方法,其特征在于,包括以下步骤:
(1)称取以下重量份原料:废陶粒砂50~80份、含铝矿石10~20份、含硅废料10~40份,通过研磨、混料和筛选得到混合粉料A;
(2)按照质量比硅酸钠:氢氧化钠:水=(305~455):(61~91):(100~140)的量,将硅酸钠、氢氧化钠加入水中,充分搅拌溶解形成溶液B;
(3)将溶液B通过喷雾形式加入到混合粉料A中同时造粒得到陶粒砂生球;
(4)将陶粒砂生球置于马弗炉中,先在500℃下烧结30min,然后在1200℃下烧结60min,随炉冷却后进行筛分,得到不同粒径区间的陶粒砂。
3.如权利要求2所述的利用废弃陶粒砂制备3D打印用陶粒砂的方法,其特征在于,步骤(1)中所述研磨过程是在搅拌磨中进行,研磨时间为2h;所述混料过程是在三维混料机中进行,混料时间为3h;所述筛选过程是用200目筛网进行筛选。
4.如权利要求2所述的利用废弃陶粒砂制备3D打印用陶粒砂的方法,其特征在于,步骤(3)中利用喷雾器将溶液B喷入造粒机中,制备成粒度为20~80目的陶粒砂生球。
5.如权利要求2所述的利用废弃陶粒砂制备3D打印用陶粒砂的方法,其特征在于,所述废陶粒砂中包括以下质量百分比的组分:SiO2 55%、Al2O334%、Fe2O3 7%、MgO 2.5%、CaO1.5%。
6.如权利要求2所述的利用废弃陶粒砂制备3D打印用陶粒砂的方法,其特征在于,所述含铝矿石为高岭土、明矾石、铝钒土中的一种或几种。
7.如权利要求2所述的利用废弃陶粒砂制备3D打印用陶粒砂的方法,其特征在于,所述含硅废料为石英砂、粉煤灰中的一种或几种。
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